Document reno69G347yzDxLry6X8ngrVv
NO. 15287*RM01
JIMMY CAMURAL MANSEL, INDIVIDUALLY AND AS PERSONAL REPRESENTATIVE OF THE HEIRS AND ESTATE OF
JAMES CAMURAL MANSEL,
DECEASED
VS.
U.S. GYPSUM COMPANY,
ET AL.
IN THE DISTRICT COURT
PLAINTIFF'S EXHmrr
DOW-2902
BRAZORIA COUNTY, TEXAS 149TM JUDICIAL DISTRICT
CERTIFICATE OF WRITTEN DISCOVERY TO THE HONORABLE JUDGE OF SAID COURT:
Defendant, The Dow Chemical Company, certifies under the Texas Rules ofCivil Procedure that the following document(s) have been served on plaintiff(s) on this the 31st day of May, 2002.
1. Exhibit List for Defendant The Dow Chemical Company.
Respectfully submitted.
MEHAFFY & WEBER, P.C.
By:
Texas Bar No. 01108800 Sandra Clark Texas Bar No. 04294520 One Allen Center 500 Dallas, Suite 1200 Houston, Texas 77002 Telephone: (713)655-1200 Facsimile: (713)655-0222
ATTORNEYS FOR DEFENDANT THE DOW CHEMICAL COMPANY
CERTIFICATE OF SERVICE
I hereby certify that true and correct copies ofthe foregoing instrument were served upon all attorneys of record on this the31st day of May, 2002, in accordance with Rule 21 and 21a of the Texas Rules of Civil Procedure.
(iti iimhtrflf
Xrthur R. Almqkist / Sandra Cl; '
Exhibit List for Dow Chemical
1. Standard Rules and Regulations (TX Div, Apr 1941, ST0014088-95):
2. Safety Rules and Regulations (TX Div, ST0014096-119):
3. Industrial Hygiene Survey of Various Operations at the Chlorine Cells (Finished 3/20/1951, ST006739-56):
4. Evaluation of Chemical Exposures Received by R.R. Spencer of Coatings Technical Service, Bldg 433 (1/22/58, ST006828-39):
5. General Plant Safety Rules (TX Div., Revised 3/24/1958, ST0014120-35):
6. Safety Rules and Safety Regulations for Paint Dept. (Jan. 1961, ST0014177-84):
7. General Plant Safety Rules (TX Div., Freeport, 5/1/1962, ST0014136-54):
8. Insulation for Personnel Protection: Pipe and Fittings (TX Div., 12/14/1962, ST053442226):
9. Letter from H.R. Hoyle of Biochemical Research Lab to R.C. Middleton of the Ludington Division of the Safety Dept (Midland, MI, 10/26/1964, ST0000018-19):
10. Exposure to Fine Dusts Encountered by Workers Cutting Various Types of Pipe Covering Material (7/21/1965, ST0000568-77):
11. Preface to Insulation Standard Specifications (TX Div., Revised 10/4/1965, ST040298391):
12. A Survey and Evaluation of Pipe Coverers' Exposures to Dusts from Asbestos Containing Insulation Materials Encountered During Routine Pipe Covering Operations Within the Midland Location of the Dow Chemical Co. (3/21/1969, ST006806-19):
13. Survey and Evaluation of Pipe Coverers' Exposures to Dusts Containing Asbestos or Fiberglass, Ludington Plant (10/23/69, Hoyle Ex. #6, ST0000647-59):
14. Safety and Loss Prevention Manual for Contractors (Feb. 1970, ST0198666-89):
15. Safety and Loss Prevention Manual for Contractors (April 1970, ST0014185-226):
16. Report by Charles G. Kramer, M.D. of the Corporate Medical Department on a course he took on asbestos (6/24/1970, ST0000703):
17. Asbestos and Health (7/17/1970, ST0002816):
18. Industrial Hygiene Survey of the Use of Asbestos in the Texas Division (7/27/1970, ST0014389-91):
19. Summary on Asbestos in the Midland Division (7/30/1970, ST0000704-5):
20. Asbestos Insulation-Status Report (9/11/1970, ST0002817-25):
21. Dust-Asbestos Sampling (10/27/1970, ST0014361-62):
22. Dust Respirator Usage (ST0614904A):
23. Environmental Conditions and Protective Equipment Specialist Team November Inspection of Magnesium I (11/6/1970, ST0654087):
24. Hazardous Dust (Houston Dow Center, 11/12/1970, ST0614903):
25. Handbook for Handling Asbestos Material (TX Div., Mar. 1971, ST0540027-39):
26. Handbook for Handling Asbestos Material (TX Div., July 1972 Rev., ST0002863-81):
27. Pipe Coverer's Handbook and Field Notes (1971, ST0000707-867):
28. Safety Standard No. 45: Asbestos (ST0002983):
29. Guidelines for Handling Asbestos Materials (9/6/1972, ST0574415-28):
30. Evaluation of Asbestos Exposures, Dow Industrial Services, Highway 332 (9/10/73, ST0684751-58):
31. Re-evaluation of Asbestos Exposures, Cell Service, A-1323 and A-1022 Bldg. (9/12/1973, ST0580542-53):
32. R&D Report on Asbestos Exposures During Maintenance, Demolition and Transite Fabrication (9/24/1973, ST0000982-96):
33. Evaluation of Asbestos Exposure to Insulators at Glycol "A" (11/21/1973, ST 001510913):
34. Safety and Loss Prevention Manual for Contractors (Nov. 1973, ST0028264-300):
35. Service Contract between Dow and U.S. Contractors, Inc. (3/12/1976, ST0533120-27):
36. Environmental Health Report on Airborne Asbestos Survey Chlorine VI, A-5024 (5/13/1976, ST0014619-24):
37. Environmental Health Report on Airborne Asbestos Personnel Monitoring in Chlorine 6, Bldg A-5024 (10/17/1977, ST0607026-30):
38. Service Contract between Dow and U.S. Contractors, Inc. (10/23/1978, ST0025437-49, plus a hold harmless agreement ST0533800-01):
39. Carpenter's Handbook (1978, ST0221386-406):
40. Environmental Health Report on Asbestos Monitoring of Magnesium IH, R-800 (1/26/1979, ST0003260-64):
41. Environmental Health Report on Asbestos Fibers Magnesium Casting B, B-842 (6/1/1979, ST0003272-78):
42. Environmental Health Report on Evaluation of Exposures to Chlorine and Asbestos at Chlorine VIA-5000 (7/14/1980, ST0606964-74):
43-. Testing Schedule for Asbestos for Brickmasons, Carpenters, Insulators, and Salvage (10/16/1980, ST0582823):
44. Protocol for Health Surveillance of the Plant A & B Carpenters (2/16/1982, ST0582822):
45. Statistical Evaluation of Respiratory System Indicators Among Insulators (ST0002927ST0002936).
46. Letter to R.L. Buell from R.E. Flake Re: Insulators (5/13/1968, ST0583215).
Exhibit List for Dow Chemical
1. Standard Rules and Regulations (TX Div, Apr 1941, ST0014088-95):
2. Safety Rules and Regulations (TX Div, ST0014096-119):
3. Industrial Hygiene Survey of Various Operations at the Chlorine Cells (Finished 3/20/1951, ST006739-56):
4. Evaluation of Chemical Exposures Received by R.R. Spencer of Coatings Technical Service, Bldg 433 (1/22/58, ST006828-39):
5. General Plant Safety Rules (TX Div., Revised 3/24/1958, ST0014120-35):
6. Safety Rules and Safety Regulations for Paint Dept. (Jan. 1961, ST0014177-84):
7. General Plant Safety Rules (TX Div., Freeport, 5/1/1962, ST0014136-54):
8. Insulation for Personnel Protection: Pipe and Fittings (TX Div., 12/14/1962, ST053442226):
9. Letter from H.R. Hoyle of Biochemical Research Lab to R.C. Middleton of the Ludington Division of the Safety Dept. (Midland, MI, 10/26/1964, ST0000018-19):
10. Exposure to Fine Dusts Encountered by Workers Cutting Various Types of Pipe Covering Material (7/21/1965, ST0000568-77):
11. Preface to Insulation Standard Specifications (TX Div., Revised 10/4/1965, ST040298391):
12. A Survey and Evaluation of Pipe Coverers' Exposures to Dusts from Asbestos Containing Insulation Materials Encountered During Routine Pipe Covering Operations Within the Midland Location of the Dow Chemical Co. (3/21/1969, ST006806-19):
13. Survey and Evaluation of Pipe Coverers' Exposures to Dusts Containing Asbestos or Fiberglass, Ludington Plant (10/23/69, Hoyle Ex. #6, ST0000647-59):
14. Safety and Loss Prevention Manual for Contractors (Feb. 1970, ST0198666-89):
15. Safety and Loss Prevention Manual for Contractors (April 1970, ST0014185-226):
16. Report by Charles G. Kramer, M.D. of the Corporate Medical Department on a course he took on asbestos (6/24/1970, ST0000703):
17. Asbestos and Health (7/17/1970, ST0002816):
18. Industrial Hygiene Survey of the Use of Asbestos in the Texas Division (7/27/1970, ST0014389-91):
19. Summary on Asbestos in the Midland Division (7/30/1970, ST0000704-5):
20. Asbestos Insulation-Status Report (9/11/1970, ST0002817-25):
21. Dust-Asbestos Sampling (10/27/1970, ST0014361-62):
22. Dust Respirator Usage (ST0614904A):
23. Environmental Conditions and Protective Equipment Specialist Team November Inspection of Magnesium I (11/6/1970, ST0654087):
24. Hazardous Dust (Houston Dow Center, 11/12/1970, ST0614903):
25. Handbook for Handling Asbestos Material (TX Div., Mar. 1971, ST0540027-39):
26. Handbook for Handling Asbestos Material (TX Div., July 1972 Rev., ST0002863-81):
27. Pipe Coverer's Handbook and Field Notes (1971, ST0000707-867):
28. Safety Standard No. 45: Asbestos (ST0002983):
29. Guidelines for Handling Asbestos Materials (9/6/1972, ST0574415-28):
30. Evaluation of Asbestos Exposures, Dow Industrial Services, Highway 332 (9/10/73, ST0684751-58):
31. Re-evaluation of Asbestos Exposures, Cell Service, A-1323 and A-1022 Bldg. (9/12/1973, ST0580542-53):
32. R&D Report on Asbestos Exposures During Maintenance, Demolition and Transite Fabrication (9/24/1973, ST0000982-96):
33. Evaluation of Asbestos Exposure to Insulators at Glycol "A" (11/21/1973, ST 001510913):
34. Safety and Loss Prevention Manual for Contractors (Nov. 1973, ST0028264-300):
35. Service Contract between Dow and U.S. Contractors, Inc. (3/12/1976, ST0533120-27):
36. Environmental Health Report on Airborne Asbestos Survey Chlorine VI, A-5024 (5/13/1976, ST0014619-24):
37. Environmental Health Report on Airborne Asbestos Personnel Monitoring in Chlorine 6, Bldg A-5024 (10/17/1977, ST0607026-30):
38. Service Contract between Dow and U.S. Contractors, Inc. (10/23/1978, ST0025437-49, plus a hold harmless agreement ST0533800-01):
39. Carpenter's Handbook (1978, ST0221386-406):
40. Environmental Health Report on Asbestos Monitoring of Magnesium IH, B-800 (1/26/1979, ST0003260-64):
41. Environmental Health Report on Asbestos Fibers Magnesium Casting B, B-842 (6/1/1979, ST0003272-78):
42. Environmental Health Report on Evaluation of Exposures to Chlorine and Asbestos at Chlorine VIA-5000 (7/14/1980, ST0606964-74):
43. Testing Schedule for Asbestos for Brickmasons, Carpenters, Insulators, and Salvage (10/16/1980, ST0582823):
44. Protocol for Health Surveillance of the Plant A & B Carpenters (2/16/1982, ST0582822):
45. Statistical Evaluation of Respiratory System Indicators Among Insulators (ST0002927ST0002936).
46. Letter to R.L. Buell from R.E. Flake Re: Insulators (5/13/1968, ST0583215).
2615 CALDER AVENUE POST OFFICE BOX 16 BEAUMONT, TEXAS 77704 TELEPHONE (409) 835-5011
FAX (409) 835-5177 FAX (409) 835-5729
MEHAFFY & WEBER
A PROFESSIONAL CORPORATION
ATTORNEYS AT LAW
500 DALLAS STREET, SUITE 1200 HOUSTON, TEXAS 77002
TELEPHONE (713) 655-1200 FAX (713) 655-0222
http://www.mehaffywober.com
1006 GREEN AVENUE P.O. BOX 189
ORANGE, TEXAS 77630 TELEPHONE/409) 886-7766
FAX($g|B6-JirW
l'l
May 31,2002
Re: Cause No. 15287*RM01; Jimmy Camural Mansel, Individually and as Personal Representative of the Heirs and Estate of James Camural Mansel, Deceased, vs. U. S. Gypsum Company, et al; In the 149th Judicial District Court of Brazoria County, Texas (MAY No. 0829-0450; Dow No. 0100915)
Mr. Jerry Deere District Clerk, Brazoria County 111 E. Locust Street Angleton, TX 77515-4678
Dear Mr. Deere:
Enclosed for filing in the above-captioned cause, please find the following:
1. Exhibit List for Defendant The Dow Chemical Company.
As noted below, a copy of same is being furnished to all known counsel of record. Please place your file stamp on the enclosed extra copy of this document and return same to me in the envelope provided herein for your convenience.
Thank you for your attention to this matter.
Very truly yours,
/S/Arthur R. Almquist
ARA/fmh Enclosure
Arthur R. Almquist For the Firm
cc: Mr. Richard I. Nemeroff Mr. William K. Tapscott, Jr.
Baron & Budd, P.C.
3102 Oak Lawn Ave., Ste. 1100 Dallas, TX 75219
123461.1
VIA CM/RRR
ST00I4088
Page 1
FOREWORD
The Dow Chemical Company is made possible by the combined efforts of every employee, by the use of capital and equipment furnished by stock holders. and by the patronage of customers who buy our products. This great enterprise will be successful if these three groups are well served and to whatever degree we understand one another.
The employee is entitled to advance as much as possible, receive courteous and fair treatment at all times, and work with the surrounding conditions maintained at the highest possible standard.
The stockholders are entitled to a fair return from their investment. It is the duty of ail em ployees to protect this investment by the proper use and care of equipment, by elimination of waste, and by giving a fair return for wages received.
The customer must receive as much or more for his money than our competitors can give if our business is to be permanently successful.
To accomplish these things in the fullest meas ure. a real challenge is continually before each and every employee.
PURPOSE OF THIS BOOK
This book is presented to you as a basis for friendly understanding. It is hoped that it will prove to be of mutual benefit, and a contributing factor in creating and maintaining harmonious relations between you, your employer, and vour fellow workers.
ABSENCE FROM WORK
Every employee should think enough of his job to promptly notify his superior when it is necessary to be absent. This is only asking good business practice. Starting January 1, 1941, all_ unexcused absences in excess of one regular work period will be investigated.
Employees will be discharged for failure to report for work for three consecutive working days unless the employee notifies his superior or the Employ ment Department and receives permission for ab sence from work.
ASSIGNMENT OF WAGES
In all cases where an assignment of wages involv ing an employee is served on The Dow Chemical Company, the employee will be automatically dis charged for cause.
BADGES
An hourly employee when hired is furnished with two badges so that it will not be necessary to change badges from street clothes to work clothes. The small badge must be in plain sight on your outer garments when you pass through the clockroom. Pay checks are given to employees only when they are wearing their badge. In case of loss, badges will be replaced at a cost of $1.00 each: this is deducted from your pay check.
CLEANLINESS
It is the duty of all Service and Construction Crews to clean-up after completing their work. Remove all the litter and scrap to places provided for the same, and turn the equipment back to the Production Department in a workmanlike manner.
Workmen are particularly cautioned to conform to special practices in various places to guard against the contamination of products. The use of a little grease or oil in the wrong place can spoil a valuable product.
By the practice of cleanliness every employee can contribute a great deal in promoting the sale of our products. Many prospective customers visit our plant. The appearance of equipment, aisles, and work benches, and the cleanliness and attitude of all
employees are very important factors in helping to
favorably impress such visitors.
DELIVERY SERVICE
Express delivery service is maintained from the Stockroom to all parts of the plant. Learn the service available from this system before making yourself subject to criticism by calling personally for items of stock.
GRIEVANCES
In case an employee has a grievance it should first be presented to the foreman for settlement. If
Hage 3
no satisfactory answer is given, the grievance should be taken to the superintendent. Any com plaint not settled in this manner may be taken up with the Employment Manager, who will present the grievance to the management.
HOLIDAYS
Six holidays are observed as follows:
New Year's Day San Jacinto Day Independence Day
Labor Day Thanksgiving Day Christmas Day
INSURANCE
Metropolitan Life and Health and Accident In surance paying $1700.00 upon death and $14.00 per week for up to 13 weeks during disability result ing from sickness or accident has been made available to all employees at a cost to them of 84c per month, the balance of the cost being borne by The Dow Chemical Company. The $1700.00 life in surance benefit is paid to your named beneficiary upon your death, regardless of cause, while the weekly sickness and accident benefits are paid when you are disabled from causes not connected with your employment.
Benefits are payable after the seventh day of disability. It is your responsibility to contact the Employment Department for the necessary blanks and instructions needed in filing your claim.
A large number of insurance checks, both large and small, have been received bv employees or their families since this insurance plan was first offered, and the benefits of the plan have been proven.
LAUNDRY SEYAKCY
Wear clean clothing. Laundry service for the
following personally owned cotton work garments
is free:
Work pants
Coveralls
Work shirts
Shop Coats
Overalls
Shop Aprons
Jackets
Shop Caps
There is danger in dirty greasy clothing, and
certain chemicals may cause irritation or damage
to the skin. Frequent washing of garments removes
these 1
`
Page *
LOANING OF COMPANY TOOLS
NO COMPANY TOOLS ARE LOANED FOR PERSONAL HOME USE. Adequate tool rooms and loan service are provided throughout the plant to supply employees with special tools: such tools are charged to the employee by tool checks or loan slip method. Tools lost or broken by work men are charged to their account, when it is felt that such loss or breakage is the result of careless ness or negligence.
MAIL
All personal mail should be addressed to your home and not to you in care of the company. For your convenience the company will handle out going mail if deposited in any one of the various department mail boxes. All first class mail received at the main office will be opened and the receiving date stamped thereon.
PAY DAYS
You will be paid by check on the 5th and 20th of each month for time worked prior to 8:00 a. m. on the 1st or 16th. respectively. Checks are available after 3:00 p. m. on pay days.
PERSONAL TOOLS
Personal tools may be taken for home work by a pass out card issued by stock room department.
Removal of personal tools belonging to employees who have been released is executed the same way. Department heads are asked to cooperate fully in this regard by giving the Stockroom Department sufficient notice in all cases of release.
PLANT RULES--BULLETIN BOARDS
Any changes in or additions to Company rules or general instructions will be posted on departmental bulletin boards before the rules or instructions are to take effect.
All notices of departmental or general interest must be approved by the department superintendent before being posted.
STOOI 4093
Page 5
SMOKING
SMOKING IS PROHIBITED AT ALL TIMES IN CERTAIN PLANTS.
In plants where smoking is prohibited, NO SMOKING signs have been posted on all building doors, or to include specific areas.
Employees violating this regulation will be auto matically discharged.
SOLICITATIONS
No solicitation of any kind will be permitted within the plant or offices of the plant, unless the same is authorized by the department head and approved by management and conducted under the supervision of the department head.
SUGGESTIONS
THE COMPANY WELCOMES SUGGES TIONS FROM ANY OF ITS EMPLOYEES AND ALWAYS APPRECIATES CONSTRUCTIVE CRITICISM.
TIME CLOCKS Every employee of The Dow Chemical Company, including the President and General Manager, has a time card and rings it regularly. No exception to this rule is made. Employees are positively for bidden to ring for each other. Ringing late will not be tolerated. You are expected to be at your place of work a few minutes beiore the whistle blows.
USE OF COMPANY AUTOMOBILES
Drivers of company cars must conform to all rules and regulations pertaining to the same. The maximum speed limit within the plant is twentyrive miles per hour. All signs must be observed.
It is not permissable for passengers to ride on the outside of cars. The maximum number of passengers in the driver's seat is two besides the driver.
Use the company car the same as you would vour own.
*160*11 0 0 1 S
Page 6
USE OF TELEPHONE
During working hours the use of the telephone for personal calls cannot be extended to employees. However, urgent incoming messages will be de livered.
Quite often urgent messages are received at the plant at times when workmen are off duty: therefore, it is important for workmen to report changes of address to their foreman and the Em ployment Department.
WASTE
Compressed air costs money; the required amount of air (5c per 1,000 cu. ft.) for two shops is 300 cu. ft. per minute. A few leaks could double this requirement and also make it impossible to reach the best working pressure. Watch for and report all leaks.
Provision for strict observance of economy in light must be planned and carried out by the fore man. Definite responsibility must be placed or assumed by the foreman to avoid wasting of light.
Water is so much used that it is very easy to misuse. Equipment requiring water cooling is quite often found shut down after the work shift but the water is left running.
Industrial wastes cause losses of millions of dollars yearly; most of it could be stopped. Your attitude toward waste is very important. You are more valuable, as an employee, if you help prevent waste.
WORKING HOURS--OVERTIME
1. The work-day shall begin at 8:00 A. M. and end at 8:00 A. M. on the following day. The work week shall begin at 8:00 A. M. on any Monday and end at 8:00 A. M. on the following Monday.
2. Time and one-half will be paid for all work done on the following holidays: N'ew Year s Day, San Jacinto Day, Independence Day, Labor Day, Thanksgiving Day and Christmas.
3. Time and one-half will be paid for all work done in excess of 8 hours in any work-day except
ST00 I 4096
SAFETY RULES
and
REGULATIONS
FOR ALL EMPLOYEES
You Are Not Required to Take Un necessary Chances-- Do Your Work the Safe Way
ST00I4097
^fety
set forth the nt of (Texas jany and to practices and .hile studying ith the probh any other There is no ran make re-
TEH
L-- B
I
ki
l> N C I C
ut to be concompany, but The practice ety measures, all dependent npioyees must eatest part at
g Things
Page !1
Take safety seriously. Be as good about protect ing your fellow workman as you would about helping them if they were hurt. It is kinder and I more profitable to all.
! COMPENSATION
J The Dow Chemical Company operates under the Workman's Compensation Law of the State of Texas in settlement of all claims for personal in juries of employees arising out of and in the course of their employment with the company. Under this act an employee who is so injured will receive com pensation at the rate of sixty percent of his weekly wage, but not more than $20.00 per week nor less than $7.00 per week for such time as he is unable to work. This payment starts on the eighth day of incapacity following the date of injury. If inca pacity continues for four weeks or longer, the first week's compensation is also paid. Various standard ized schedules have been incorporated in the law in regard to the length of time for which compensa tion shall be received for total, or partial, tempor ary or permanent disability. During the first nine ty-one days after the injury the employer furnish es reasonable medical, surgical and hospital service.
All matters pertaining to compensation are handled by the Employment Department.
FIRST AID
It is the policy of the Company to maintain, for the benefit of its employees, the best possible First Aid facilities. The First Aid room is located at the garage. 901 building. The Department is sufficiently
equipped to handle emergency first aid cases. The
personnel includes four graduate nurses. There is a , nurse on duty twenty-four hours a day.
The First Aid is maintained solely for you: con sider it your duty to use it at any time ior even ( the slightest injury received while at work.
It is considered to be in order to call at the First Aid for relief treatment for minor AILMENTS NOT ATTRIBUTABLE to your employment, when such treatments will permit you to complete your
Thinkl Is It Safe?
Page 12
regular work period. You are urged, however, to consult your family physician as neglect to do so often results in acute cases. The First Aid is not intended to completely diagnose such cases and no responsibility is being assumed in rendering relief treatments of this nature.
SAFETY ENGINEERING The Dow Chemical Company is showing, through the Safety Department, its sincere interest in main* taining safe working conditions for its employees. One member of the department devotes his full time to safety engineering, establishing safe prac tices, and safety education throughout the plant. The facilities of this Department are constantly at the service of any of the employees of the company. If you have a carefully thought out suggestion for improving working conditions from the stand point of health or safety--explain it to your fore man and submit a written report of the suggestion to the Safety Department. At the Safety Department a complete display of safety equipment is arranged to assist foremen and employees in selecting the proper equipment to safely handle their jobs. You are urged to visit this room and keep in touch with the new types of equipment.
Accidents Are Preventable and Repeatable-- Be Careful
ST0014 I 00
Page 14
therefore, are asked to read them carefully. After you have read and studied the booklet, sign the printed statement on the last page and return it to the Safety Department.
GENERAL RULES
1. While no attempt will be made to set up definite procedures in case of a serious accident, the following general rules should be studied as a guide:
(a) The ambulance and First Aid phone number are in large letters on the cover of the phone book. Call the ambulance immediately. Call the First Aid as well, so that the nurse on duty may call for help if needed.
(b) Be calm and explicit. Deliver the message so that there is no chance for a mistake. Be sure to give the building name, the build ing number, and the type of accident.
(c) Unless specific instructions have been given you what to do---remove the person from further danger, make him as comfortable as possible, and make sure that there is no danger from exposure.
(d) In moving an injured person to a place oi safety, extreme care must be exercised as there may be fractured bones. Move the patient as little as necessary.
(e) In cases of bad acid or caustic burns, flood the burned area with water--and lots of it-- and get the patient to the First Aid. Running water is far better than just immersing the burned area.
2. It is hereby declared to be a rule of The Dow Chemical Company, that WHENEVER AN EMPLOYEE RECEIVES AN INJURY. EVEN THOUGH IT BE CONSIDERED SLIGHT. HE MUST REPORT AT ONCE TO THE FIRST AID STATION. If the foreman or crew leader is present, the injured employee shall advise him of the injury before reporting to the First Aid; but if the fore man or crew leader is not present, then the injured
We Need Your Help in Preventing Accidents
Page 15
employee shall go direct to the First Aid. THE FOREMAN SHALL MAKE A WRITTEN RE PORT TO THE FIRST AID OF THE DETAILS OF ALL INJURIES RECEIVED BY EMPLOY EES UNDER HIM.
Prompt and proper treatment of a minor injury will prevent unnecessary suffering and loss of time. Our First Aid staff is for your benefit and protec tion--many bad cases of infection have been caused by home use of iodine by men in our own plant.
IDENTICAL INJURIES Tliisman spent ten minutes in the First Aid room*
This man wait ed 5 days be fore reporting injury--He lost 12 weeks
3. The practice of fellow employees removing foreign particles irom eyes is strictly forbidden. This practice often results in serious if not per manent injection to the eye. Each time a particle enters the eyeball a slight laceration is made which is easily infected. Go to the First Aid.
4. We will not be responsible for any bills of outside doctors unless a properly written order granting permission to call upon such doctors is obtained in advance.
Learn by the Experience of Others
STOOIUI 03
5. Horse play, scuffling, throwing things, and fooling with compressed air in the plant are dan gerous and will not be tolerated.
6. Few men realize the danger in the use of compressed air. The air hose should never be directed toward an individual.
Before using compressed air. as an aid to re moving dust from clothing, the equipment used for the purpose must meet the approval of the Department of Safety.
7. Personal cleanliness is an important item in the maintenance of healthy and safe working conditions:
(a) Always wash up before eating--particularly if you have been handling paint, lead, or chemicals.
8. Watch the Safety Bulletin Boards. Each poster is a lesson in itself; you can easily profit by reading it.
9. When you see a warning or danger sign, be sttre you are safe before going ahead. Xot to do so is to invite injury.
10. Boards with nails sticking up must not be left lying around. When you see such boards, turn them over, pull the nails, or put the boards where thev can do no harm.
11. Do not climb through, under, over, nor be tween railroad cars. Wait until the train passes, or walk around the end of the train. With the exception of the engine or switching crew, no one is allowed to ride yard locomotives or freight cars.
12. Do not attempt to lift or push objects which are too heavy for you--ask for help when you need it. Learn to lift the right way to avoid strains; bend your knees, keep your body erect: then push upward with vour legs. It is much easier and safer.
13. When working on any kind of a pressure line be sure that the supply is shut off and a warning sign placed on the supply valve. Never open or close a valve on a pipe line unless you know it is saie to do so.
Practice Safety Yourself--Others Will Follow You
Page 17
ASPRAINED BACK
Causedby WrongLifting
14. All excavations, open manholes, and other places where persons might fall must be protected l>v suitable railings and lights.
15. When walking on plant roadways walk on the ieit hand side nt the road, unless paths or walks are established.
16. The speed limit in the plant tor all com pany and private cars or trucks is twenty-five miles per hour. This limit must not be exceeded.
17. The driver of a company car. truck, or taxi is responsible for the condition of his car while it is entrusted to him. Any irregularities of brakes, lights, horn, fumes in cab. or general operation of the automobile must be reported to the garage on the regular form provided tor the purpose. It is requested that drivers of plant cars keep on the roads designated for travel and refrain from driving on areas not designated for car traffic as much as possible.
Good Housekeeping is Good Safety
18. Pickup trucks carrying passengers must be equipped with the standard seating arrangement. The Service Department is responsible for seeing that new pick-up trucks are so equipped before be ing issued to individuals or departments.
19. It your work requires you to enter other departments, familiarize yourselves with the rules and dangers of these departments.
GOGGLES--CLOTHING
1. Goggles or face shields must be worn as pro tection on the following jobs:
(a) While working on or around magnesium cells.
(I>) While working with or pouring molten metal.
(c) On any grinding operation.
(d) On any chipping operation--goggles only,
fe) Breaking up concrete or brickwork--goggles only.
NATIONAL
SArtTT
COUNCIL
Wear Safe Shoe*
(f) Any welding or burning operation.
(g) When the handling of chemicals is particu larly hazardous.
2. You are required to wear goggles when and where you are instructed to do so. For the safety of your eyes do not neglect to do it. Protect your eyes when working near welding equipment.
3. Where the heat is excessive, men are advised to wear sweatbands on the forehead to keep per spiration out of the eyes. Anti-fog sticks may be secured front the Safety Department. A small amount applied to goggle lenses will prevent steam ing. Goggles should be adjusted to fit the face com fortably. Head straps should fit over the tops of the ears and well down on the back of the neck.
4. You are especially cautioned to roll up your sleeves, not wear a necktie, and not wear gloves while working around any revolving machinery.
5. Rings, watch chains, key chains, loose jack ets are all potential accident makers and should not be worn in the shops or around moving ma chinery. The results from an accident caused by one of these factors are often extremely serious.
0. If you are working where there are heavy fumes or dust you will be required to wear the respirators provided for your protection.
TOOLS--EQUIPMENT
1. Safety devices and guards are tor your pro tection. Keep them in place at all times. Removing or tampering with safety guards is forbidden by law.
2. In using grinder--be sure that the tool rest is within one-eighth of an inch of the wheel and that guards and hood provided are in proper posi tion and in good repair. Wear goggles for all grind ing work, unless the grinder is equipped with an approved glass shield.
3. Stop machinery to clean, oil. adjust or repair by pulling the main switch. Lock the switch or hang a warning sign on it if there is a hazard due to someone starting the equipment before it is ready.
You Can't See Through a Glas Eye
TOO 14 106
C/3
STOO14107
1`nge -1)
[tBoROoKElNs! N O N a w A f t T V COUNCIL 4. Never use defective punches, wrenches, chisels or other tools. Flying chips from tools with mush roomed or split heads cause many injuries. In the use of personal tools, the man is wholly responsible for the condition of his tools. If you are using plant tools insist upon getting proper tools for the work you have to do. 5. All gears where exposed to contact must be guarded. b. All drive belts exposed to contact, except those moving so slowly that there is no possibility of danger, must be properly guarded. Proper lacing of belts is important. The joint should be made close and smooth. Rawhide lacing must be used in cases where belts are to be shifted by hand. 7. Whenever possible, line shafts should be shut down while belt is being put on--employee should be stationed at starting switch as a precau tionary measure. Never allow inexperienced men to replace belts on moving pulleys.
You Can't Depend on Luck; You Can on Safety
hings, and it are dan-
the use of never be
aid to reiment used >val of the
irtant item fe working
particularly it. lead, or
ards. Each asilv profit
;er sign, be iot to do so
mst not be >oards. turn iards where
er. nor berain passes, . With the *ew, no one reight cars. ijects which ;n you need oid strains: : then push r and safer.
a pressure off and a alve. Never unless volt
Follow You
11. Keep the floor space around machinery as clean and as free from obstructions as possible. Loose material, oil. and grease are all definite hazards in any location, particularly >o around machinery of any kind.
CRANES
1. Never stand or walk under a crane load. Obey the man handling the load from the floor;
We Can Furnish Goggles, But Not Eyes
STOO14109
Page J2
listen for the crane horn or other signalling de vice. When entering a shop floor, over which there is a crane, look for the crane--determine its loca tion before crossing the floor.
The responsibility of carrying a load safely is placed upon the crane operator. You must hook your load to his satisfaction at all times.
2. Riding a load handled by a crane or riding crane chains or slings is strictly prohibited with the exception of crews working on steel erection.
3. The practice of moving oxygen or acetylene cylinders, by means of cradling one or more cylin ders in the crane chain, is strictly prohibited. Gas cylinders are not to be hoisted or lifted, under any circumstances, by crane except in specially con structed holder.
4. Certain men are designated as crane oper ators. Xo one other than these operators are to operate a crane except in case of emergency and with the permission of the Shop Superintendent.
5. Do not leave a load hanging or hooked on. Make sure that everyone is out from under load, lower and place load, unhook immediately and hook up chain or remove sling. See that hook or chain is hoisted above head level immediately after unhooking.
ti, \iter finishing any repair work, make sure that all tools and materials are removed from crane or track.
7. Xo employee is allowed to work under a sus pended load without same being blocked in such a manner that any failure of crane or part would not allow load to fall on him.
ELEVATORS
1. In case any elevator equipment is found out of repair, the Machine Shop Office must be notified at once. Do not try to repair the elevator yourself.
2. All elevator gates are to be in a closed po sition--except at the level at which the elevator
A Good Safety Record is a Fine Recommendation
} V
ignalling dewhich there line its loca-
ad safely is t must hook es.
ne or riding hibited with :l erection.
or acetylene more cylin-
jhibited. Gas d. under any )ecially con-
crane oper ators are to .ergency and perintendent.
' hooked on. under load,
ediately and .hat hook or .diately after
. make sure moved from
under a sused in such a rt would not
is found out st be notified ttor yourself.
a dosed pothe elevator
ammendation
Page 23
car is standing. If the gates do not close auto matically, do not consider that as an excuse for leaving them up.
3. Do not allow material, rubbish, stock, etc., to accumulate near elevator gates. The space directly in front of the elevator shaft must be kept clear at all times.
4. When doing any repair work on elevators of any type--close and lock, or tag, the main switch.
5. The following definite rules apply to the use of the various man elevators in the plant:
(a) When you step onto the elevator--grasp the handle with one or both hands and face the belt.
(b) When shutting the elevator off, after reach ing your floor, make sure that no one is riding the elevator at the time.
(c) No material or tools are to be carried on the elevator which cannot be easily and safely handled with one hand. No hand tool or material over 18 inches in length is to be carried.
(d) The practice of placing tools, tool boxes, or material of any kind on the elevator steps--to be carried to a higher or lower level--is strictly prohibited.
(e) Report to your foreman, or the Safety De partment. any hazardous conditions around the elevator landings.
LADDERS
1. Never use a ladder which is defective in any respect, such as with broken or split side rails or rungs. The tool room is equipped to renew broken rungs with rung replacers.
2. In placing ladders--the best angle at which to lean the ladder is that in which the horizontal distance irom the foot of the ladder to the base of the wall or beam against which the ladder is resting is one-quarter of the length of the ladder.
Think How Much Suffering First Aid Prevents
w
*
ST00I4I 10
Haere '4
LADDERS
3. When a ladder is left standing over night, tie up the top of the ladder.
-1. Never place a ladder on a slippery floor un less the base of the ladder is securely anchored so it cannot slip, or unless somebody is holding the ladder at the bottom.
5. Use caution when carrying boxes, tools, chaintalls. or other material in your hands when climbing or descending a ladder. Use a rope, or crane, with excessive loads so that both hands will be free to grasp the ladder.
6. Never descend a ladder while facing outward. 7. Be careful when carrying ladders in aisleways, through doorways, or around blind corners. Always carry it with the end ahead of you ele vated high enough to clear a man's head in case you should meet some otie unexpectedly.
Keep Fit By Keeping Clean
1N Cl
ver night, tie
ery floor unely anchored dy is holding
boxes, tools. hands when
;e a rope, or : both hands
ciug outward. iers in aisleblind corners. I ot you ele-
head in case dly.
an
WELDING EQUIPMENT
1. Never look at an electric arc with the naked eye. When observing or working near arc welding operations--the eyes must be protected from direct exposure.
2. Heavy canvas (or metal) screens must be used to afford protection to all others from elec tric welding wherever possible, particularly when welding is being done in the shop.
3. When welding wherever there is the least chance of causing a fire, keep a fire extinguisher within reach. Welders are- required to have a quart hand extinguisher as a part of their equip ment.
4. Gas motor driven portable generators or air compressors must not be located inside build ings. The exhaust vapors are extremely dangerous and these machines must be operated out of doors.
5. Never allow oil or grease in any form to come into contact with part of the oxy-acetylene welding equipment. An explosion may occur if you violate this rule.
6. Use extreme care in handling gas cylinders. Do not drop tanks over steps, off of trucks or platiorms.
7. Keep cylinders away from salt and other corrosive chemicals and fumes.
8. Carrying or lifting tanks by crane or hoist is absolutely forbidden, unless a sling or cradle constructed for this purpose is used--see Cranes --3. page 22.
9. Put nothing on top oi tanks--you may damage the safety plug or regulator, or interfere with the quick closing of the valve. Valves must be closed when cylinders are not being used.
10. Cylinders must be secured to prevent their being knocked over while in use.
11. All cylinders should be protected against excessive rise ot temperature. On storing cylinders in the open--see that they are protected against extremes of weather.
Report Every Injury
e n iio o is
12. Foremen and welders should study thor oughly the more detailed "Safety Precautions for Arc and Acetylene Welders."
13. The Boiler Shop is equipped to service and repair all acetylene welding equipment. Worn and defective gauges, regulators, etc., must be turned in for repair.
ELECTRICAL EQUIPMENT
1. There is no line of work where it is more necessary to be always on the alert for danger. Do not take chances.
2. Do not fail to report any electrical trouble whatsoever, or any apparently dangerous install ations, to your foreman.
3. Employees not authorized are forbidden to work or tamper with any electrical wire or equip ment.
4. Treat all circuits, so far as possible, as if they are alive, even though you believe them dead.
5. In handling live or control parts on circuits such as are exposed on switches, switchboards, etc., use only one hand if possible. When closing a switch, close it solidly and abruptly. This will greatly reduce the chance of the switch "arcing".
f<. Electric wires which seem to be unused or are hanging free are sometimes charged and are dangerous. Report them but do not touch them.
7. When opening a switch, in order to shut down a machine for maintenance or repair work, the switch must be properly tagged with a warning or do not start sign. When the work is done get the proper authority to start the equipment.
8. Get the voltage off the line--in case of any electrical fire. Open the switch or circuit breaker, or call the power house to have the switch opened on that line.
9. In case of fire on or near electrical equipment, do not use water to extinguish the fire. Proper extinguishing units of C-O-Two or Pyrene are lo cated near all large electrical machines.
Foot Note--Remove Nails from Boards
*#
*
4-W
S T 0 0 I4 I14
tudy thorautions for
service and Worn and be turned
T
it is more for danger.
ical trouble rous install-
orbidden to re or equip-
ssible, as if e them dead. s on circuits switchboards, Vhen closing lv. This will tch "arcing". ;f% 'jniicpfj AJ* *ged and are ouch them. to shut down ir work, the a warning or done get the t. i case of any rcuit breaker, switch opened
cal equipment, : fire. Proper Jyrene are lotes.
i Boards
Page 27
10. In case of severe electrical shock--remove the person from the source of current immediately and call the ambulance and First Aid at once.
(a) Use a dry coat, dry rope, a dry stick or board or any other dry non-conductor to move either the victim or the wire, so as to break the electrical contact.
(b) If the victim is conducting the current to ground and is convulsively clutching the live conductor, it may be easier to shut off the current by lifting him than by leaving him on the ground and trying to break his grasp.
(c) Open the nearest switch if that is the quick est way to break the circuit.
11. Accidental electric shock usually does not kill at once, but may only stun the victim and for awhile stop his breathing. Under these circum stances artificial respiration is recommended im mediately.
FIRE PROTECTION
1. In case of fire--call the Dow operator and report the fire, giving building name and number and location of fire. In cases of fires after regular working hours, the watchman will notify all pro duction and service men directly affected by the fire.
1. Learn the location and proper use of the fire fighting equipment in your department.
(al Do not use water where extinguishers are provided.
Xever hang up an extinguisher. If you have used one or see one which is not on a hook, notify the Pipe Shop at once.
(c) Use extreme caution in fighting hot fires in closed rooms or badly ventilated areas. Toxic products of combustion often provide a ser ious hazard.
3. The plant fire department is under the super vision of the Pipe Shop. All maintenance of fire fighting equipment, automatic sprinkler systems,
Safety and Efficiency Go Hand in Hand
I'aoe AS
PORE
1
EdOOl?BflllCaif 1
OVERYOUR LIFE 1 ANDOUR property!
Acc>f) it
GETATABIE'
u.
:i
! > <J j f :-s ' i'T 1 i
* ,-A f !/ i
1
tr-'v-a<<g&f ' .-
MATlONAl* SA**TV
COUNCIL
fire hydrants, and fire hose is taken care ot by that department. Notify the Pipe Shop at once if any ot the above equipment is not in perfect working order.
4. Never pile any material on any floor beyond its load limit or to a height within less than eight een inches of the level of any sprinkler head.
5. Except in times of immediate use. aislewavs, passages, stairways and elevator approaches must
be kept clear; a dosed passage might result in the
loss of an entire plant. There must be unrestricted passage to all fire hose and fire protection equip ment at all times.
fj. Keep the places around you clean. Put all oily waste, rubbish, or papers in the covered containers provided for that purpose.
7. Do not work on any electrical apparatus or wiring unless it is part oi your work.
Double Your Caution in Rain, Snow or Sleet
Page 29
8. Some plants of The Dow Chemical Company are a definite fire hazard because of the materials handled. These particular plants are prominently posted with signs prohibiting smoking and the carrying of matches while in or around the build ings and requiring the personal O. K. of the plant superintendent before doing any welding in or around the plant--look for these notices and obey them to the letter.
9. When doing any welding--use extreme cau tion in lighting the torch and make sure that the hot slag will not fall where there is danger of its igniting inflammable material. Welders are re quired to have a hand extinguisher as a part of their equipment.
r
9 1 1'llOOlS
rare of by that once if any of rfcct 'vorking
. floor beyond :ss than eightikler head. use. aisleways, proaches must it result in the >e unrestricted )tection equip-
an. Put all oily :red containers
l apparatus or
ow or Sleet
P*Re TO
LABORATORY SAFETY
The importance of safe practices in all laboratorywork or handling of chemicals cannot be overem phasized. While the previous sections of this book let apply to laboratory workers as well as to others, the following instructions must be kept particularly in mind. Your laboratory director or supervisor is aware of the importance of safety and will welcome your suggestions.
GENERAL--HANDLING CHEMICALS
1. Keep all bottles labeled. Serious accidents have resulted from neglecting this simple pre caution.
2. Know the materials with which you are work ing so that you are able to handle them properly and caution others in their use.
3. Deposit waste chemicals in crocks or jars provided for the purpose. These waste jars must be emptied daily.
4. IX THE CASE OF A CHEMICAL BURN --IMMEDIATE FLUSHING WITH WATER IS THE BEST EMERGENCY TREATMENT.
5. Keep goggles or a face shield on hand and use them on any hazardous operation. Remember, it is YOUR eyesight which is being protected and accidents usually happen when least expected.
6. Aislewavs and approaches to apparatus and lire equipment must be kept clear so that quick exit is unhampered.
7. Guard your apparatus with suitable glass or metal shields so that those nearby are safe. Men working near one another on different projects are not aware of what each may be doing.
8. Read carefully the specific safety instructions tor your particular laboratory. Each man must realize his individual responsibility for the safety of himself and others.
A safety minded person is a valuable asset to plant and community
ed '
3. locatit quantity safety \
4. ing or' lines orl use. In I tainerj throughJ
of cable
Don't!
nST0014 I
iboratory overem-
his bookto others, .rticularly ervisor is
welcome
accidents tple pre-
ire workproperly
or jars $ must be
L BURN VTER IS N'T. hand and emember. ected and ctcd. -atus and hat quick
glass or .ate. Men ejects are
structions tan must he saietv
et to
E. Protective clothing--rubber gloves, sleeves, aprons, etc.
F. Safety shields--shatter-proof wired glass and steel shields.
Make sure you understand the relationship be tween your job and the available equipment before you begin work. Your immediate superior or the Safety Department will be glad to answer any questions you may have.
FLAMMABLE LIQUIDS
1. Low boiling flammable liquids should be heat ed with steam whenever possible.
Z. Extreme care must be used when distilling flammable liquids. Look over any nearby equip ment for open flames, electric heaters or open re lays. any of which may provide a source of ignition for flammable vapors.
3. Flammable liquids must the stored in a safe location in metal containers except when small quantities are to be used immediately. Regulation saietv cans are available for this purpose.
4. Be careful to avoid static electricity in pump ing or transferring flammable liquids. Metal tanks, lines or other equipment should be grounded beiorc use. In transferring flammable liquids, both con tainers should be grounded either by contact or through the use of battery clips and a short length of cable.
Don't let familiarity with your job make you forget safety
S T00I4I18
Pajte 32
PRESSURE EQUIPMENT
1. When working with pressure apparatus, make sure of the temperature and pressure for which the equipment has been designed.
2. Always work with a safety factor of at least two over hydraulic tests made on pressure equip ment. Under unusual conditions a greater safety factor may be necessary and the choice of equip ment must rest upon an individual who has had such authority delegated to him. Be certain the strength has not changed due to corrosion or high tempera ture use since the last hydraulic test.
3. Conform to recommendations in the use of frangible disc safeties.
4. Make sure you are not exceeding allowable working pressures on the pipe and fittings being used.
5. The volume of a pressure vessel must be considered carefully in relation to the volume and possible expansion of the material with which you may be working. In general a pressure bomb should not be filled to more than six-tenths of its capacity. High temperature operation will reduce this figure.
6. When opening pressure equipment, do not remove any nuts or bolts on the closure before first loosening all closure fastenings. Make sure the closure is free, releasing any pressure, before removing any bolts or nuts completely.
7. NEVER ATTEMPT TO REMOVE OR BLOW OUT EQUIPMENT OR PIPING WITH OUT FIRST BEING POSITIVE THAT ALL IN TERNAL PRESSURE HAS BEEN RELIEVED OR THAT YOUR FACE AND EYES HAVE BEEN ADEQUATELY PROTECTED. DO NOT DEPEND UPON GAUGE READINGS TO IN DICATE LACK OF PRESSURE.
NEGLECT OF THIS SIMPLE PRECAUTION IS THE GREATEST SINGLE CAUSE OF CHEMICAL ACCIDENTS. IF THE ACCI DENT RESULTS IN PERSONAL INIURY YOU ARE THE ONE TO BLAME AND THE ONE TO SUFFER.
Your job is only as safe as you make it
"ncpipt ffiPY Biochemical Research Department
03 i |l/2. WUi I THE DOW CHEMICAL COMPANY
Sub.lect: INDUSTRIAL HYGIENE SURVEY OP VARIOUS OPERATIONS AT THE CHLORINE CELLS, BLDGST
261, 196, 157, 295/ 256,
270, 505/ 207.
Pile T34.21-21-5(E\) a
Chg.
1219
' '
Rec'd. 5/7/48
Pin'd. 5/20/51
Work by H.' Hoyle
E. J. Schneider
ST006739
to:
I. F. Harlow, Bldg. 509 (l) R. M. Hunter, Bldg. 261 (1) W. R. Perry, Bldg. 261 (l) Medical Department (1)
Att: H. H. Gay, M. D., Bldg. 256 Safety Department (l)
Att: S. M. MacCutcheon, Bldg. 401
0 vyVr/
THIS REPORT IS THE PROPERTY OF
THE OCR CHEMICAL COMPANY
SUMMARY AND CONCLUSIONS 1. Significant amounts of chlorine, sufficient 'to cause, inflammation and swelling of the respiratory system from short periods of exposure, were found in areas where men were working on and among tie chlorine cell series. 2. Men working in these areas have been getting by without
severe exposure by using respirators, however. It must be kept in mind that excessive amounts of chlorine above the maximum allowable
concentration of 1 p.p.m. for an-eight-hour exposure do exist among the cell series.
5. No excessive amounts of chlorine were found in the making of bleach solution at the cell brine plant, 505 building.
4. Excessive concentrations of chlorine occurred in the loading of ton cylinders with liquid chlorine when the delivery line became plugged and insufficient time wa3 taken to purge the
connecting lines to the cylinder before removing them.
, OlUUiti lilltai ucocai ui jL/epartraeii. T54.21-21-3 Page 2
5. No excessive amounts of chlorine were found during the normal loading of cylinders and no odor of chlorine was noticed during normal operations to purge., test and load tank cars.
6. Excessive amounts of chlorine and sulfuric acid were found while dumping the sulfuric acid drying tower to the sewer.
7. No excessive amounts of alkali dust were found among the chlorine cell series. .
8. No significant amounts of mercury vapor were found at the discharge of the vacuum pumps for the mercury arc rectifiers.
9* Excessive amounts of pitch dust must be considered to exist, since men who are working at the pitch grinding operation do become photo-sensitized and must limit their outdoor activities.
10. Large amounts of graphite dust were found during the loading of plates into the buckets to be impregnated with phenol formaldehyde resin solution. Since the loading operation involves only an hour or so, the exposure to the graphite dust can not be considered excessive.
11. The graphite dust concentrations found in the machine shop were well within the limits for an inert dust.
12. The worker using the band-saw wa3 found to be exposed to more fine dust than workers at the other machines, possibly because there was no spot exhaust ventilation provided.
13- No excessive amounts of formaldehyde or phenol vapors were found during the making of the phenol formaldehyde resin or during the various drumming operations.
ST006740
I *) .Z9 0 0 1 S*
, oxuuaeuuuckx ac*ai*u<j department T54.21-21-3 Page >
14. The millions of particles per cubic foot of air of asbestos was found to run higher than the maximum allowable concentration of 5 for an eight-hour exposure for the handling of dry asbestos in cover ing the cell diaphragms. Since the exposure occurs only eighteen times a day for a short period with a total exposure of less than two hours, the amounts of asbestos found cannot be considered excessive.
CHLORINE I. Significance of Chlorine Exposure
1. For many years a gas concentration of 1 p.p.m. (by volume) has been used as a standard for evaluating workmens' exposures. Recently there has been some expression of opinion that 2 or J p.p.m could be tolerated up to 8 hours dally without adverse effect. Gas concentrations much above 3 p.p.m. unquestionably produce irritation
t
(tissue injury) to the eyes, nose, and throat; concentrations above 10 p.p.m. may cause serious effects on single relatively short expos. ures. Beginning at about 3 p.p.m. chlorine causes unmistakable pain In the eyes, nose and throat to which very little tolerance develops. This painful action serves as an excellent warning of the presence of harmful concentrations of gas. There appears to be no evidence of chronic effects from repeated exposures at concentrations of less than 2-3 p.p.m. (concentrations having no immediate acute effects). Repeated exposures above 2-3 p.p.m., however, may maintain an Irritation of the eyes and respiratory passages, produce an erosion of the teeth, and possibly a nonspecific debility.
Tp^.21-21-3
Page 4 2. To a large extent the data of Table I, II, III, and IV merely give numerical expression to what has been apparent by sensory perception and experience, that excessive gas concentrations are encountered rather frequently If not routinely. Considering the nature of the operations and that much chlorine comes from unpreventable or accidental leaks, it 'may not be practical to reduce these concentrations of chlorine. Accordingly,* it is necessary to emphasize the need for proper respiratory protection, the training of workmen, and the provisions for handling leaks. The results emphasize the desirability of medical examinations to assure the workmen are receiving adequate personal protection. If the men show no evidence of injury that is persistent or frequent, then our principal additional recommendation is that every opportunity to lessen chlorine contamin ation be utilized. II. Observation and Presentation of Data 1. The odor of chlorine was ever present throughout the cell buildings and from time to time it was noticed that the men were required to use their respirators in order to gc about their work. 2. Air samples were collected at several locations ana on different days. The results of the air analyses are collected in Table I and II and can be compared with the accepted maximum allowable concentration of 1 p.p.m. for an eight-hour exposure.
ST006742
Biochemical Research Department T34.21-21-3 Page 5
TABLE I
Vapor Concentration of Chlorine Pound Among the Cell Series in Building 137
Location
p.p.m. (by Volume)
1. Center aisle between series 45 and 46 (10-4-49)
and 1.44 cloudy/raining
2. Center aisle between series 41 and 42 (10-4-49)
0.72
It It
tt
3* Center aisle between series 37 and 38 (10-4-49)
0.31
ft If
II
4. Center aisle between series 33 and 34.(10-4-49)
0.31
ft II
It
5. Between series 45 and 47
(10-4-49)
0.31
11 n
It
6. Between series 41 and 43
' (10-4-49)
2.16 " n tl
7. On top series 43 8. Between series 46 and 48
(10-5-49) (10-5-49)
1.13 cool and clear 6.80- " ii U
9. Between series 42 and 44 10. On top series 46 11. Between series 35 and 37 12. On top series 35 13. Between series 31 and 32 14. Between series 38 and 40
(10-5-49) (10-5-49) (10-5-49) (10-5-49) (10-5-49) (IO-5-49)
4.00 " If 3.30 " it 1.44 " 11 1.44 " it 2.16 " it 1.13 " if
II
n
It
II
00
--1
tt
CD
O
cn
It --1
15. On top series 36 16. Between series 32 and 34
(IO-5-49) (IO-5-49)
1.13 n tt O.31 " ti
tt CD II
17. Near compressors
(10-5-49)
0.31 " tr
It
18 Center ai3le near 13,14, 15.16,17,18 series
19. On top series 39 repairing leak
(10-6-49)
20. Near two mechanics repairing corapressor(l0-4-49)
0.31 " " and
2.16 cloudy /raining
4.40 " ti U
21. On top series 46 (when back pressure
operator added water)
(10-6-49) 7.30 " tt tl
22. Between series 15 and 17
(10-6-49) 0.72 " 11 II
23- On top series 15 24. Between series 16 and 18
25* On top series 16 2o. On top series 36 repairing leak
(10-6-49) (10-6-49)
(10-6-49) (11-18-49)
0.31 " 1.44 "
11 tt it
II
It tt
0.72 5.29
" cool
and
1clear
J jjxucucw-lwh.* "wjwui w4 TJ4.21-21-5
Page 6
TABLE II
Vapor Concentration of Chlorine Found Among the Chlorine Cell Series in
Building 295
Location
p.p.m. (by Volume)
1. Between series 93 and 95 2. Between series 92 and 94
(11-18-49) (11-18-49)
O.36 clear and cool 0.36 " It ir
3- Between series 93 and 95 and on top (11-18-49)
4. On top series 103
(11-18-49)
0.72 " II 11 1.53 " II tt
5. On top series 104
(11-30-49)
1.13 " U tt
6. On top series 110
(11-30-49)
0.36 " n it
7. On top aeries 109
(11-30-49
4.4
11 tt
8. On top series 103
(11-30-49)
3.6 ' - tt u>
9. On top series 101 (men setting it up)(11,-30-49) 14.8, 9.4 tt it
10. On top series 99 11. On top series 98
(11-30-49) (11-30-49)
11.5 10.8
" 11 "n
it tt
12. Center aisle near series 92, 93, 94, 95 (li-30-49)
2.56
it n
3. In the chlorinating of the cell caustic for bleaching
*iU900JLS
solution at the cell brine plant no irritating or excessive amounts
of chlorine escaped during the normal operation.
The results of air analyses collected during the preparation
of the bleaching solution are shown in Table III
TABLE III Vapor Concentrations of Chlorine Found in the Making of Bleach Solution. Building # 303
Location__ p.p.m. Chlorine (by Volume)
1. Platform near tank for making bleach solution. In the fumes at the start of bubbling chlorine through the sodium hydroxide
2. In the fumes after one-half hour of bubbling 3. In the fume3 after one-hour of bubbling and
finishing batc^i up
1.1 1.1
1.1
Biochemical Research Departraer. T34.21-21-2 Page 7
S'iZ.900iS
The possibility of exposure to chlorine vapors during
the loading of tank cars and cylinders was investigated, sensory
perception usually being employed a3 a measure of exposure. If a
good vacuum was pulled on the tank car and the connecting lines purged,
there was little chance for exposure when removing the valves and
testing the car for moisture. With properly repaired valves and
tight connections, there was no exposure during loading.
5. In the loading of cylinders, an inside Job, there was
more chance for exposure to chlorine. During one visit the delivery
line for the liquid chlorine became plugged. In removing the connect-.
Ing lines,, insufficient time was allowed for purging and excessive
r
amounts of chlorine were found to exist.'
6. During normal operation of the filling of the cylinders
-no excessive amounts of chlorine were found. The results of air
analyses taken during the leading operation of ton cylinders are
collected in Table IV.
Table IV
Vapor Concentrations of Chlorine Pound During the Filling of Ton Cylinders of Liquid Chlorine, Bldgf 270 (11/15/50)
Location
p.p.m,
1. Breathing zone of operator as he disconnected purge lines from empty ton cylinder
5*12
2. Breathing zone of operator a3 he disconnects
lines from full ton cylinder of liquid chlorine (line became plugged aid Insufficient time was allowed for purging)
8.2
v
Biochemical Research Department
T?4.21-21-2
Page 8 7. In the operation of changing the drying towers in the cell buildings, high enough concentrations of chlorine and sulfuric acid were encountered to saturate a respirator. Table V shows the concentrations of chlorine found during this operation.
SULFURIC ACID (PLUS CHLORINE) I. Significance of Sulfuric Acid Exposure
1. Sulfuric acid fume or mist has an acute irritating action not too different from that of chlorine'. The problem presented by this mixture is practically the same as that presented by chlorine alone. The exposure is short and the concentrations sufficiently low that no great hazard is presented by the operation. It is one that occurs .regularly, however, the one can question whether or not it is really necessary. II. Observation and Presentation of Data
1. The odor of sulfuric acid fumes was masked by the chlorine. Air analyses during the operation showed the presence of considerable acid fumes, however, the exposure was of short duration.
2. The results of the air analyses are collected in Table V and can be compared with the maximum allowable concentration of 0.25 p.p.ra. for an eight-hour exposure.
(Table V - page 9)
ST006746
Biochemical Research Department T34.21-21-3 Page 9
Table V
Concentrations of Chlorine and Sulfuric Acid Fumes Found During the Emptying of a Drying Tower to the
Sewer, Building 137
Location (by volume)
p.p.m. cl*
p.p.m. H2SO4 (by volume)
1. Operators breathing zone as he opens valve to release sul furic acid from tower to sewer (first series of towers)
50 (5 min.)
5.7 (5 min.)
2. Area near sewer after the tower was dumped (first series
of towers)
1-3
2.3
5. Operators breathing zone as he opens valve to release sulrfuric acid from tower to sewer (second series of towers)
13.8 (5 min.)
3.9 (5 min.)
.4. Area near sewer after the tower was dumped (.second series of towers)
2.9
2.1
ALKALI DUST (PROBABLY SODIUM CARBONATE)
ST006747
I. Observations and Presentation of Data
1. No maximum allowable concentration has been established
for alkali, however, based on plant experience, no significant amounts of sodium hydroxide were found.
2. The presence of finely dispersed titratable alkali was
checked by air analyses among the various cell series and the results
are collected in Table VI.
Table VI
Location
Dust Concentration of Sodium Hydroxide Found
Among the Chlorine Cells Series in Buildings
lj?7 ar*d 295
Dldg. 137
~Mgs./c u.meter as NaOH
1. On top of series 47 2. Between aeries 45 and 47 5. Between series 41 and 45 4. Between series 50 and 48 5.. Between series 42 and 44 6. Between series 14 and 16 7. Between series and 56
8. Between series 15 and 17
10-6-49; 10-6-49 10-6-49 ;iO-6-49j
(10-6-49) (11-18-49 (11-18-49)
(11-18-49)
same as blank
(I
It
2.44 2.44 2.18
Diocneciicai nesearcn Depart,r.ent T34.21-21-3 Page 10
Table VI (cont'd) --Hiag: 29b--
9. Between series 92 and 94 10. Between series 95 and 97
11. Between series 109 and ill 12. Between series 104 and 106
'11-18-49) (11-18-49)
11-18-49)
(11-18-49)
1.95 0.66 0.80
1.14
MERCURY I. Observations and Presentation of Data
1. Air is constantly being evacuated from the mercury
arc rectifiers and discharged into the rectifier room. The pos
sibility of some mercury vapor being given off was checked by
ST006740
sampling at the outlets of the vacuum pumps. The results of the
air analyses are collected in Table VII and can be compared with
the maximum allowable concentration of 0.1 mg./cu. meter. These
concentrations of mercury have no significance whatever.
Table VII
Vapor Concentrations of Mercury found in the Rectifier Room, Building 137 (il-15-50)
Location
1. Directly beneath the outlet of the low pressure vacuum pump for G-2 skid of mercury arc rectifiers
2. Directly beneath the outlet of the low pressure vacuum pump for G-l skid of mercury arc rectifiers
3. Directly beneath the outlet of the low pressure vacuum pump for H-2 skid of mercury arc rectifiers
4. General air sample taken between skids G-l and H-2. Circulating air shut off for winter conditions
Cone. Hr. Vapor (by volume) ^0.006 ngs./cu. meter /0.006 mgs./cu. meter ^0.006 mgs./cu. meter /0.006 mgs./ cu. meter
ST0067U9
, Biochemical Research Deoartment TJ4.21-21-5 Page 11
PITCH I. Significance of Pitch Exposure
1. Coal tar pitch from many different sources has produced a variety of effects in the skin: photosensitivity; acne and other dermatosis; pigmentations and growths, some of which are benign, others malignant. It is said that about half of the cancers at tributable to occupational exposures are due to pitch. The heavier fractions and t ars of some petroleums and of shale oil have similar actions. One obtains the impression from published information that the rather heavy exposures among pitch workers cause a high incidence of skin injuries.
2. It is apparent that the men handling pitch in the chlorine cells come in direct contact with the material, resulting in prolonged and repeated'contacts upon some portions of the body. The data in Table VTII Indicate a moderately dirty atmosphere.
5. The data in Table IX represent counts of small particles, roughly of particle size 0.1 to 5 microns which may be inhaled. This data Indicates that relatively small amounts of pitch dust are being inhaled. Since the literature contains no reference to toxic effects attributable to Inhalation, we are not greatly concerned about inhal ation of pitch dust.
4. Excessive skin contact with pitch dust is to be controlled by arrangement and design of the process to eliminate manual handling and dispersion of dust,by personal protection of workmen,and measures to assure a high degree of personal cleanliness. The clothing and bath requirements on these Jobs have been indicated. It is recommended that the men working directly with pitch be given medical examinations at regular iiy:ervals.
oiocneaiicai ne scarce ^cunrccenc T34.21-21-3 Page 12
II. Observations and Presentation of Data
1. Several exhaust hoods had been installed to control the v-
dust exposure when grinding pitch. The men working on the pitch
grinding equipment, however, through known experiences, are apparently
exposed to amounts of pitch sufficient to cause photosensitivity.
2. The results of air analyses taken in the worker's breath
ing zone and in the work area during various operations encountered
in pitch-grinding are collected in Table VIII.
Table VIII
Dust Concentrations of Pitch Pound During the
Grinding and Handling Operations in Preparation of Waking; Cell Cement - Building 196
Location
Cone. Mgs./cu.
1. Breathing zone of worker as he opens metal drum of pitch tar and breaks up the contents
63
2. Breathing zone of worker as he shovels broken pieces of pitch into the grinder and dumps buckets of pitch into mills
306
3. Breathing zone of worker as he rakes
pulverized pitch from the cyclone anc shovels it into the buckets
Cli*
4. Breathing zone of worker as he sweeps area after grinding and filling buckets'
453
5. Breathing zone of worker as he operates the cable hoist to dump bucket of pulverized
pitch into hopper fir the mixer
209,249
3. The results of dust counts taken in the general area i
during the various pitch grinding operations are shown in Table IX,
ST006750
(Table IX - page 13)
xiocaeciical T34.21-21-3 Page 13 Table IX
aesearcn Deoarcnent
Dust Concentrations Pound During the Various Pitch grinding; operations and in the General Area
Location (Breathing zone samples taken whenever possible)
m. p. c. f.
(average of several counts)
I. Shaking out broken pitch from metal drum
5
2. Breaking up lumps
7
3. Shoveling broken up pitch into grinder'
8
4. Dumping buckets of ground pitch to mills
5
5. Sweeping up area where pitch is ground .
7
6. Raking out pulverized pitch
5
7. Filling buckets with pulverized pitch
5
8. Sweeping area where buckets are filled
2
9. Dumping bucket to mixer
5
ST00675I
10. Gen. atmosphere near foreman's desk
5
II. Area in front of small mixer while dumping cement to the small mixer with pitch
4
12. Area in front of small mixer while dumping the
pitch cement mix
:
4
15- Area in front of small mixer with men working on poured casting
3
14. Area of building where men are working to prepare the cell forms
5
GRAPHITE DUST
I. Significance of Graphite Dust Exposures
1. There are a few reports of lung injury (pneumoconiosis)
among persons working with graphite. Nearly all reports have
dealt with natural graphite containing an appreciable amount of
other minerals so that it is not definite that graphite dust alone
has an adverse effect.
T34.21-21-2
Page 14 2. It is apparent that considerable amounts of graphite are
dispersed in the air, but the counts of particles susceptible to inhal
ation fail to indicate any exposures that are questionable. If workmen
were regularly and uniformly exposed to counts of more than 50/000,000
particles per cubic foot, correction would be called for.
II, Observations and Presentation of Data
1. A dusty atmosphere was created when a worker used an
air hose to. remove the loose graphite from the plates before loading.
There was still sufficient loose graphite remaining on the plates to
make the loading of them very dusty.
2. The results of air analyses made during the loading oper
ations are shown In Table X.
Table X
Dust Concentrations of Graphite Pound During the Loading of Plates into the Buckets in Preparation for Precnatlnr with P.P., Bid;;. 261*
Location
Dust Cone. : Mg./cu. meter
ST005752
1. Breathing zone of worker blowing loose graphite off a stack cf plates with an air
hose (room closed up for winter conditions)
22o0
2. 5reathing zones of two workers as they load a bucket with graphite plates
2370
3. Several dust counts were taker, curing the plate leading
and in the general atmosphere. The results of these counts are shewn
in Table XI. These values can be compared with the maximum allowable
concentration of 50 m.p.c.f. for ar. inert dust.
4. Several dust counts were taken in the machine shop, both
during the operation of the machines and in the general atmosphere
through the area. The results of these counts are shown in Table XI al30.
Biochemical Research Deoartment T34.21-21-5 Page 15
Table XI
Dust Concentrations of Graphite Pound During the Loading of Plates and Various Operations in the Machine Shop.
Treating Room
Location (Sample taken in the breathing zone of worker whenever possible)
m.p.c.f. (aver age of several
counts)
1. Blowing the loose graphite off the plates before loading them
50
2. General atmosphere in the room after blowing 3. Piling the plates into the buckets
35 50
4. General atmosphere of the treating room after
finishing the loading of the plates *
10 min.
15 min. 20 min. 30 min.
/ , 45 min.
5. General atmosphere in the treating room in the morning when the plates are unloaded
20.1 28.3 35.2 30.8 41.0
2.0
Machine Shoo
ST006753
6. General atmosphere in the machine shop early in the morning before work is started
7. Cutting corners off of boards at band saw
8. Running plates through bevel machine
7 20
8
9. Near new machine for grooving boards
10
10. Near old machine for grooving boards 11. Placing boards in machines
9 8
12. Removing boards from machines 13. Where operator sits after loading machines
9 10
14. Blowing small area from machines so board Is locked in 15. Blowing machine off for cleaning
11
10
16. Sweeping up area around machines
8
(Table cont'd on page 16)
iiocr*eaica.i. rteseircn depart cent; T5^.21-21-3 Page 16
Table XI -(confd) 17. General atmosphere near foreman's desk 18. General atmosphere near crib
8 v. 5
19. General atmosphere other end ofshop
5
20. . General atmosphere office area
4
21 Janitor sweeping floor
5
FORMALDEHYDE
I. Significance of Formaldehyde Exposures
1. None of the exposures measured during normal operation
were excessive. II. Observations and Presentation of Data
1. In the making of the phenol formaldehyde resin, the odor
of formaldehyde was noticed throughout the room, however, only during
the blowing 6f the mixing tank was there evidence of eye irritation.
2. In all cases where air analyses were made, the concentration
of formaldehyde found was below the maximum allowable concentration of
5 p.p.c. The results of air analyses are collected in Table XII.
ST00675li
PHENOL
I. Significance of Phenol Exposures
1. None of the exposures measured curing normal operation
were excessive.
II. Observations and Presentation of Data
1. Very little odor of phenol was noticed during the various
operations of making phenol formaldehyde resin. The results of the
air analyses can be compared with the concentration of 10 p.p.m. phenol
found through past company experience to be an acceptable limit.
2. Table XII also shows the results of air analyses for phenol
concentration.
Biochemical Research Departmen
TJ4.21-21-3 Page IT
Table XII
Vapor Concentrations of Formaldehyde and Phenol Found During Various Operations of the Phenol Formaldehyde Resin Process, Building 256
Location (Winter conditions - doors and
windows closed)
p p tn Formaldehyde
(by volume)
p.p.m. Phenol
(by volume
1. General air sample taken in front of reactor and near operator's desk (reactor-up to temp.)
2. From an elevated platform between the reactor and mixing tank (reactor up to temp.)
1.0 1.0
0.40 0.87
5. Next to the mixing tank and oper ator's desk
4. Near the mixing tank as phenol wa3 blown in from trailer outside
5. Near the mixing tank as formaldehyde was pumped in from storage tank
6. Near the mixing tank as air was blown to mix concents
7. Near the mixing tank and operator's desk after blowing had stopped*
0.44
1.27 2.8, 2.6 4.0
0.69 1.04
8. Near the vacuum still (operating) in the area where operator spends considerable time making insulating plugs
1-5
9. Breathing zone of operator filling 100 gal. drum with evaporated P.F. solution
2.9
10. Breathing zone of operator filling four
50-gal. drums with neutralized and evaporat ed
P.F. solution for the Texas Division
2.4
11. Operators breathing zone filling six 50 gal. drums of formaldehyde for interplant use. (work done outside on cold, windy day)
.60
1.19 1.11 0.87
co
Biochemical Research Department
T}4 .21-21-3 Page 18
ASBESTOS
I. Observations and Presentation of Data
1. The handling of dry asbestos in making up a slurry of
caustic, water and asbestos does offer an exposure to finely divided
particles of asbestos.
2. The results of dust counts taken in the breathing zone of a Worker as he weighs, dumps, and stir3 the asbestos into the slurry are shown in Table XIII. These values can be compared with the max
imum allowable concentration of 5 m.p.c.f. for an eight-hour exposure. None of the exposures measured during normal operation were excessive
since the duration of exposure is short. Table XIII
Dust .Concentrations Found During the Handling of Dry Asbestos in the Covering of Cell Diaphragms
Location (samples taken in worker'sbreathing zone) _____________________________________________________
1. Dumping bag of weighed asbestos (48 lbs.) to slurry tank
m.p.c.f. (average of several ________ counts)
8
2. Stirring and mixing the asbestos with water 3. Weighing out a bag of asbestos
10 5
ST006756
bc-8
V
Biochemical Research laboratory
OFFICE COPY The Dow Chemical Company
070 7
$S0s
Noted E.E.D. Af-
' FEB 07 1958
EVALUATION OP CHEMICAL EXPOSURES RECEIVED BY R. R. SPENCER OF COATINGS TECHNICAL SERVICE, 433 BUILDING
Pile: T2.1-1-S Chg.: 1219.. oS Date: 1-22-58 * . By: J E. Peterson
Signed
Date 1J/-2<r/s-p
J
PROBLEM
THIS REPORT IS TliL PROPERTY OF
THE DOW CHEMICAL COMPANY
Recently, R. R. Spencer has become ill. The Environmental Research Laboratory was requested to determine chemical exposures received by him, and to assess these data.
ST006828
CONCLUSIONS
1. Exposures to airborne materials during the formulation, mixing, and calendering of vinyl asbestos tile in 433 Building were evaluated on 12-23-54 and on 1-15-58. Results of these evaluations are used to assess exposures received by R. R. Spencer during his work with this material.
2. Prom December 1953 to December 1954, R. R. Spencer worked with vinyl asbestos tile formulations, and in the course of that work was occasionally exposed to somewhat excessive concentrations of airborne asbestos.
ST006829
y Biochemical Research Laboratory T2.1-1-65 Page 2
During this period of time exposure to lead occurred, but his blood lead level on 3-7-55 was only 0.024 mg./lOO cc. blood, a .. normal figure. Exposures to cadmium during this period were to airborne concentrations of "4 0.7 mg./m^" at intermittent periods. No effect is expected as a result of these exposures.
3. From the first part of 1955 to late 1956 Mr. Spencer worked mostly with latex in concrete, and exposures to vinyl-asbestos tile ingredients were reduced accordingly.
4. From the last part of 1956 until the present he has been working with vinyl-asbestos tile formulations in a supervisory
/
capacity. During this work he was probably exposed a maximum of 1-2 days per week to airborne dust concentrations of less than 3 mppcf of a material analyzing 20-30# asbestos, less than 5# SiOg, and about 0.02# cadmium. No effect can be expected from such exposure.
5. If Mr. Spencer's difficulty is the result of chemical exposure, the c-*U3itive agent 13 unknown at present. Further air analyses are to be made during a time when chlorinated polyethylene is used as the resin binder in the tile formulations.
ST006830
y'
Biochemical Research laboratory T2.1-1-65 Page 3
PRESENTATION OF DATA
R. R. Spencer has been ill with a lung difficulty, and overexposure to chemicals encountered during the formulation, mixing, and calendering of vinyl-asbestos tile formulations was suspected to be.the cause of his illness. The Environmental Research laboratory was requested to determine and evaluate his exposures.
On 12-23-54 an environmental survey of the vinyl-asbestos tile formulating operation was made by S. R. Johann; the results of this work were reported on 5-5-55 (Pile Number, T2.1-1-32). This survey found that air concentrations of "inerts" (asbestos plus calcium carbonate), barium, and lead were too high for repeated 8-hour exposures, and even though exposures were not that prolonged, recommended the installation of local exhaust ventilation. Cadmium was determined in the air samples, but In all cases the amount present was below the limit of sensitivity of the analytical, technique employed, leading to air concentration figures of "less than" 0.66 mg./m^ and "less than" 0.45 mg./m^.
As a result of this Investigation several changes were made. First, the use of lead and barium compounds in the formulation wa3 sharply curtailed. Second, operational techniques were changed so that each batch was completely formulated before mixing in the Banbury or Baker-Perkins machines, and mixing in these enclosed machines wa3 always to be done prior to
Biochemical Research laboratory T2.1-1-65 Page 4
Third,"canopy hood3 were installed over the large 2-roll mill and over the calender, but not over the small 2-roll mill usually used for preliminary compounding of these formulations. Finally, the Building Products group recently moved into new quarters where a bench-type hood is always available to control duat from dry mixing.
In connection with the environmental survey of December 195^> samples were taken for blood-lead determinations for .the men involved on this project. R. R. Spencer's blood lead concentration was found to be 0.024 mg./lOO cc. of blood, a normal figure, indicating insignificant exposure to lead. The oijher two men involved also had normal blood lead values.
On 1-15-58 a second environmental survey of the vinyl-asbe3tos tile operations was made, partly to assess the value of indicated changes in reducing exposures of personnel, and partly to gain more Insight into the chemical exposures that R. R. Spencer may have received recently.
The ingredients used in vinyl-asbesto3 tile formulations have quite well to the same basic recipe for over a year.
STO0683 I
y'
Biochemical Research laboratory T2.1-1-65 Page 5
ST006332
The recipe is as follows: Material
Weight Ratio
Resin May be chlorinated polyethylene or resin 2716, the copolymer of 15# vinylidene chloride, 8556 vinyl chloride.
Dioctyl phthalate or tricresyl phosphate
17.5 2.25
Monoplex S-38 An epaxldlzed oil purchased from Rohm and Haas.
Metasap 624 Contains cadmium laurate
Aluminium stearate
Paraffin wax
LesimltCalcium carbonate
No. 18 graining sand A very fine sand
Titanox RA50- Titanium dioxide
Asbestos shorts, type 7M
2.25
1.5 0.1 0.1 39*B 12.5
5*0 19.0
With the exception of dioctyl phthalate and monoplex S-38, which are liquids, all of these materials are dry powders, and normally are weighed into a stainless steel mixing bowl in the open. This operation takes about 5 minutes. The mixing bowl is then placed under a mixer within a hood, mixed for a few minutes, and then the two liquids are added. After further mixing, the batch (which is still a dry powder) is poured into a paper bag held within the hood.
ST0Q6833
Biochemical Research laboratory T2.1-1-65 Page 6
When it is done, weighing and blending of the ingredients takes place at a maximum frequency of about 3-half-days per week; an average frequency is difficult to establish because two or three week3 may pass with no activity in this area at all. Mr. Spencer normally would be involved in about 10# of this work which is usually done by a lab technician.
Dry powder from the paper bag is poured directly into the BakerPerkina or Banbury mixer - usually the Banbury. Here the material is forced into a heated mixing chamber with an air-powered ram and is mixed for about two minutes. The resulting mass is semiplastic, and is removed (sometimes with difficulty) from the mixer and carried to the differential speed heated (200-300P.) 2-roll mill. On this mill it is further blended and occasionally marbilizing chips are added. Such blending may take from 2 or 3 minutes to a half-hour depending upon the difficulties encountered.
After being thoroughly mixed on the 2-roll mill the plastic mass is carried to the calender (basically a cooler heated 2-roll mill) a few feet away. Here the material is squeezed to a pre-determined thickness by a pass through the rolls; the surface of the resulting strip is improved by a second pass through this machine. The strip of tile material is then cut into pieces of the* correct size for testing with a shear. Prom Banbury mixer to finished pieces of tile may take from 15 minutes to an hour or so for a single batch.
Biochemical Research laboratory T2.1-1-65 Page 7
The maximum frequency of this Job is about the same as for weighing and blending, 3 half-days per week, and again, an average frequency is almost impossible to establish. For reasons of safety, two men always work together in these operations; Mr. Spencer has been associated with about 80$> of this work since the latter part of 1956.
On 1-15-58 several air analyses were made during vinyl-asbestos tile manufacture. Air sampling equipment used was the Bau3ch and Lorab dust counting microscope and the electrostatic precipitator. Results of these air analyses are presented in Table I. Samples 1-11 were taken with the B and L dust counting microscope and the concentrations are expressed in terms of millions of particles per cubic foot of air. (mppcf). Samples 12-14 were taken with the electrostatic precipitator, and normally concentrations would be expressed as milligrams of air contaminant per cubic' meter of air (mg./nr*), but the samples were unfortunately of too short duration to obtain weighable quantities of dust.
ST006034
Biochemical Research laboratory T2.I-I-65
Page 8
Table I
Description
Dust Concentration, mppcf
An air sample taken directly over a paper bag of dry materials shaken to produce dust. This sample was mainly to establish the size range of the airborne particles.
Breathing zone sample as a paper bag of formulation was dumped into the Banbury mixer.
Sample of fume from the hot semiplastic mass as it was withdrawn from the mlxerf not a breathing zone sample.
Breathing zone of a man removing the serai-plastic mass from the Banbury mixer with steel picks.
Breathing zone while working the material-on'the 2-roll mill.
Breathing zone while working the material on the 2-roll mill.
Breathing zone of man as he put the material through the calender.
Breathing zone while cutting the tile to size on the shear.
Room air in the office.
Breathing zone of lab technician as he added dry asbestos fiber to the mixing container on a scale in the laboratory.
Most particles ^ in diameter, average about 2-3 X
3.2
0.7
to --1 O 1.0 0 . cn CO CO 0.9 tn
0.2
0.7
0.5
0.2 1.4
ST006835
Biochemical Research Laboratory T2.I-I-65
Page 9
Sample No. 11
12 13 14
Description
Dust Concentration, MPPCF
Inraedlately outside of the bench hood where the dry batch of material was being mixed.
0.5
Length of Time of Sample
Electrostatic precipitator sample in the breathing zone while formulation being mixed in the Banbury.
2 min.
Dust Cone.mg./m.^ ___________
Too little to weigh
Breathing zone while work
ing the formulation cn the 2-roll mill.
Too little to measure.
Sample taken in bench hood over the container where the
dry mixture was being stirred. This sample was taken only to
determine the relative propor
tions of the dust constituents in air.
CaCO, - Main Constituent
Asbestos - 20-3058
sio2
<5%
Cd 0.0256
ST006836
The re3in used for the tile formulation involved in the work described in Table I was resin 2716, consisting of the polymer made from 15# vinylidene chloride, 8556 vinyl chloride. Analysis of Sample 14 was by x-ray diffraction and emission spectrograph; the organic materials ar rxt "seen" by this method.
y'
Biochemical Research Laboratory T2.1-1-65 Page 10
ST006837
The dust concentrations shovm in Table I may be compared with the appropriate Industrial Hygiene Standards, listed in Table II. Industrial Hygiene Standards are concentrations which may be Inhaled as much as 8 hours per day, 5 days per week indefinitely without ill effect.
Table II
Industrial Hygiene Standards
Material
Standard
Asbestos
5.0 mppcf
Silica (quartz) Cadmium Calcium Carbonate Resin 2716
5.0 mppcf 0.10 mg./ra^ 15.0 mg./m^ probably 15.0 mg./m^
;
An examination of Tables I and II readily shows that at no time were the standards for asbestos or silica exceeded. Since the dust counting microscope determines the number, not the welght of particles in the air some assumptions must be made before the cadmium exposure can be evaluated: (l) assume that the-dustencountered near the Banbury mixer, 2-roll mill and callender had the same particle-size distribution as the dust of the dry mixture (confirmed by dark-field microscopic examination); (2) assume the du3t particles were spherical with an average diameter of 2.5J1! (3) assume the density of the particles was approximately 2.0 g./cc.
ST006838
./ Biochemical Research laboratory T2.1-1-65 Page 11
Using these assumptions, the weight concentration of dust corresponding to the highest observed particle concentration (3-2 mppcf) would be 1.85 mg./m.'^. Then, assuming that the particles were 0.02^ cadmium, the air concentration of cadmium was about 0.0004 mg./m. , well below the 0.10 mg./m^ Standard, especially considering that all of the assumptions made were conservative.
Thermal decomposition products of the resin and plasticizers used could conceivably be the cause of trouble except that a great amount of experience at Dow and at other companies with these materials has shown that no adverse effects are to be expected even under much worse conditions than have been prevalent in 433 Building.
Remaining as a possibility is the dust and/or thermal decomposition products from chlorinated polyethylene, a new material. A survey will be made when this material 13 again used in vinyl-asbestos tile formulations in order to determine what materials are inhaled, and in what concentrations. Also, this dust, along with the dust of other materials, i3 soon to be investigated by the Toxicology Laboratory to determine the degree of irritation caused by subdermal injections. Thi3 investigation should help to decide whether or not Mr. Spencer's lung injury could have been caused by the resins used in vinyl-asbestos tile formulations.
./'
Biochemical Research Laboratory T2.I-I-65 Page 12
The bench hood used in the laboratory for dry mixing was evaluated
by measuring air velocities at the face`of the hood with an Anemotherm
Air Meter. The attached "Hood Survey Data Sheet" is self explanatory
regarding findings and reconmendatlons.
ST006839
ST00I4I20
S T 0 0 I4 I2 I
GENERAL SAFETY RULES
REVISED MARCH 24, 1958
INDEX
GENERAL SAFETY RULES A. FIRST AID 8. CONDUCT C. VEHICLES AND TRAFFIC D. PROTECTIVE EQUIPMENT 8. CLOTHING E. MACHINERY, TOOLS, AND EQUIPMENT F. HOUSEKEEPING G. LADDERS AND SCAFFOLDS H. RED TAGS AND PERMITS
I. ELECTRICAL J. EXCAVATIONS AND FLOOR OPENINGS K. PRESSURE CYLINDER AND SAMPLE BOMBS L. EMERGENCY PROCEDURE M. RADIATION
PAGE
1 1 2 * 5 * 9 10 11 12 12 13 13
4STOOI 122
T
GENERAL SAFETY RULES A completely safe operation is one of the important ob
jectives of The Dow Chemical Company and the following 1 rules are designed to aid in achieving that objective. It
is impossible to list here all safety rules that are neces sary to insure maximum safe conditions and work habits. These rules cover only the general points and more de tailed and specialized rules are in effect in various areas and departments throughout the plant.
The omission of any specific rule from this list should not be regarded as minimizing the importance of such rule, and in no way relieves the individual employee of i the responsibility for doing every job in the safest man i ner possible.
i
i> Violation of any safety rule is considered a serious of fense and this offense is subject to a penalty that may include discharge, depending on the seriousness of the violation.
The primary responsibility for personal safety lies with each individual and the effectiveness of the accident prevention program of the company depends upon the wu0i6u63fi6u coop era lion of every employ
A. FIRST AID 1. Whenever an employee receives an injury, even though it be considered slight, he must report as soon as possible to First Aid for treatment. The employee must notify his supervisor of the injury, preferably be fore reporting to First Aid, or as soon as possible there after, depending upon the circumstances. 2. Employees must not attempt to remove foreign part icles from the eyes, except by washing with water. If a corrosive material, such as caustic or acid, gets in the eye, it must be washed immediately with running water
-1-
and the washing continued for at least fifteen minutes. The ambulance must be called so that washing of the eye can be continued enroute to the Industrial Medical Department. If any doubt exists as to the corrosiveness of the material that may get into the eye, the washing procedure must be carried out. 3.If corrosive chemicals come in contact with the body, the affected parts should be washed with running water for at least fifteen minutes. If necessary, cloth ing should be removed to make sure that adequate wash ing is being accomplished.
B. CONDUCT 1. All employees are expected to know and abide by their departments' safety rules. 2. Horseplay in any form must not be engaged in by employees in the plant or on duty. 3. Running in the plant must be avoided except incase of an emergency. 4. Pedestrian paths and walkways must be used when ever provided. In their absence, employees using streets and roadways must walk on the left side, facing ap proaching traffic. 5. Employees must not climb through, under, over or between railroad cars except in performance of assign ed duties. 6. Employees entering other departments must familiar ize themselves with and be governed by the written
safety rules of that department. 7. Compressed gases must not be used for cleaning of clothes or the body. 8. Safety belts, with lifelines attached, ate to be worn by employees when performing work in elevated posi tions where the use of scaffolds or ladders is impracti cal and where a slip might result in a serious accident.
-2-
*lZ I *11001S
*
9. Employees must not make inoperative, as a matter of convenience, such safety devices as relief valves, solenoid controls and swing guards. 10. Unsafe short cuts, such as walking across ditches on pipelines and cutting corners to save a few steps, must be avoided. 11. Before beginning work in areas where contact with corrosive chemicals is possible, employees must famil iarize themselves with the location of the nearest safe ty shower, eye bath and telephone. 12. All containers such as bottles, jugs, or cans of hazardous chemicals must be properly labeled. This in cludes all chemicals that are toxic, corrosive or flam mable. 13. All glass containers of one gallon or more capaci ty must be properly crated before shipment in the plants and while in use. Alt glass containers of material that is toxic, corrosive or flammable must be properly crated while being transported. 14. Employees, when riding on open type trucks, must not stand up or hang their feet over the sides. 15. Smoking is strictly prohibited in the plant in those areas posted with "No Smoking" signs. Reference is made to Section. VI B1 of the Employee's Manual for further information on policy regarding smoking.
16. Maintenance personnel must report to the operat ing supervision before beginning work in a production plant area on a non-routine job, and daily thereafter un til the job is completed. Upon completion of the work, operating supervision must be notified that they are leaving the area. 17. Employees must familiarize themselves with the location of emergency equipment such as gas masks, fire extinguishers and fire blankets in the area in which they work.
-3-
ST0014125
18. Employees must not drop or jump on to a transite roof. 19. Flammable materials must not be dumped into sew ers without permission of the supervisor.
C. VEHICLES AND TRAFFIC 1. The driver of company motorized equipment is re sponsible for the condition of the equipment while it is entrusted to him. Any irregularities of brakes, lights, horn, fumes in cab or general operation must be report ed to the garage on the regular form provided for this purpose. 2. Drivers of plant vehicles must keep on roadways designated for such traffic as much as possible. 3. All traffic signs in the plant must be obeyed. Emer gency vehicles on call may be exempt, but drivers of same shall be responsible for driving with due regard for the safety of others. 4. The speed limit in the plant is 25 miles per hour unless otherwise designated by signs. The speed limit must not be exceeded except in emergencies. 5. The maximum number of people who may ride in a pick-up truck is three in the cab and six seated on the pick-up bed or on approved "built in" seats. Under no circumstances should arms or legs hang outside the vehicle cab or bed. 6. Hauled material that overhangs the sides or ends of trucks must be properly flagged. 7. Personnel newly authorized to operate motor scoot ers must be given proper instructions in the safe opera tion of the same. 8. The speed limit for motor scooters is 20 miles per hour. The removal of, altering or otherwise tampering with the carburetor or governor settings to increase the speed is prohibited.
-4-
x> <-
1*
9 Z I*ll0 0 1 S
9. No more than two people may ride on a package car scooter (box in front) and then only when the passenger is seated inside the box. 10. The load capacity for pickup model No. 781 scoot ers is 500 pounds. Not more than two passengers and the driver may ride in pickup model scooters and then only when an approved seating arrangement is provided
by the Garage. 11. Night operation of scooters without lights is pro
hibited. 12. Passengers standing on Plant route busses must stay to the rear of the front row of passenger seats. 13. Motor scooter engines must not be left running while scooter is unattended.
D. PROTECTIVE EQUIPMENT & CLOTHING
1. When entering any designated compulsory eye pro
tection area, all persons are required to wear eye pro
tection as specifically approved for that area.
2. Proper type goggles must be wom when chipping,
grinding, buffing, cleaning welds, loading or unloading
material or any similar operation or condition where fly
ing particles constitute an eye hazard.
3W* nonortUmiiobniihlUlltl/lj.l^nunprpoiwwvtswHu
va/wVn/ nplWrrslWMVpWliVpHn mn>WiieJtt hwvo*
worn by employees when transferring corrosive materi
als (such as acid, caustic, etc.) from one container to
another by pouring and when taking process samples of
such materials.
4. Employees working with or around electric arc weld
ing or cutting must wear approved eye protection.
5. It is recommended that employees also wear proper
goggles under the following conditions:
(A) When handling carboys or glass bottles of cor
rosive liquids.
(B) When a high wind is blowing.
-5-
(C) When riding motor scooters or open trucks on plant roadways. 6. All employees subject to any hazardous exposure, including dust, chemicals or toxic irritants, must wear adequate protective equipment approved by their super visor and the Safety Department, such as: Head pro tection, rubber jackets, slicker suits, coveralls, fire resistant clothing, protective sleeves, spats, gloves, aprons, protective footwear, respirators and gas masks. Company-furnished clothing and protective equipment must not be altered without permission. 7. All employees must wear personal clothing that is safe and proper for their jobs. 8. In no case shall an employee in the plant work in an undershirt, shorts only, or stripped to the waist. 9. Metal safety hats must not be worn in areas that are electrically hazardous. Plastic hats are available and recommended for such use. 10. Adequate protective equipment, such as slicker suits, rubber gloves, rubber boots, as well as face and eye protection must be worn when breaking into pipe lines, vessels or other equipment th.at may contain acid, caustic, or any other corrosive material. 11. Adequate ventilation must be maintained when using solvents. If ventilation is inadequate, then res piratory protection must be worn. 12. When flammable liquids are transferred from one metal container to another, proper bonding must be pro
vided to prevent accumulation of static electricity. 13. All full-face gas masks must be sent to the Safety Department at least annually for checking.
E. MACHINERY, TOOLS, AND EQUIPMENT 1.Machines must have all guards in place before be ing operated, unless the specific job is approved by the
supervisor.
2. Defective tools are to be tagged with a "Defective Tool Tag" and returned to the Tool Room for repairs. 3. Tools, material or equipment must not be intention ally dropped or thrown from a higher to a lower level un less adequate precautions have been taken to make sure that no injury to persons or damage to equipment will occur. 4. Neckties, loose clothing and jewelry, such as tie chains and watch chains, must not be worn around mov ing machinery. 5. Air pressure on pneumatic tools must be bled down before disconnecting them from the air supply. 6. Tool rests on grinders must be set not more than 1/8 inch from the wheel. Buffers are not be to operated with tool rests. 7. All pedestal and bench grinders and buffers must have a satisfactory guard over the wheel. Portable grind ers and buffers must have a satisfactory guard over the wheel except in cases where special conditions make the use of a guard impractical and the employee's super visor has approved its use without a guard. The guards on wire buffing wheels mounted on pedestal or bench grinders should be cut back at the bottom about 30 de grees from the vertical center line of the guard. 8. Grinding on the side of emery wheels must be done only on wheels that are designed for this purpose. 9. Moving machinery and process equipment in service must be shut down before adjustments or repairs are made except as follows: If it is not feasible to shut
the equipment down before performing work upon it, then it is necessary for department supervision to:
(A) Determine for each item of such equipmentwhat jobs must be performed with a listing of those jobs made for the use and information of the workmen and
-7-
their supervisors. Any non-listed jobs of any nature are not to be done. (B) Prepare a detailed safe job procedure for each listed, permitted job and also a list of personnel authorized to perforin these jobs. 10. Gloves must not be worn while using grinders, but* fers, or drill presses unless permission to do so is se cured in advance from the foreman. 11. Gasoline tanks on motorized equipment must not be filled while the engine is running. 12. Blue flags must be used on railroad tracks when the entrance of a train would present a hazard to per sonnel or equipment. Removal of blue flags must be authorized by the person who put them up. 13. The use of nonferrous tools is to be given considera tion on jobs and in areas where an explosion or fire haz ard exists. 14. In die event it becomes necessary to enter a vessel that may not be completely free of hazardous contents, a safety belt and life line must be wom in addition to the other protective equipment needed. Safety belts and life lines must be worn by those entering vessels when ever it is deemed advisable by the supervisor. 15. Vessels moved to the shops and salvage must be cleaned whenever practical, and tagged as to condition and previous contents. 16. Employees must not tide a load that is being handl ed by a crane. The riding of crane slings is prohibited,
except where a bosun's chair is provided or permission is given by the supervisor. 17. Spring-loaded snap-on "Cleco" quick hose con nections must be reserved tor use on air and water ser vice. A part ot the "Cleco" connector must not be left connected to a process line. This does not exclude the use of other type quick connectors on the above or other service.
STOOI 4 I 30
18. "Boss-type" hammer union connectors must be used on steam hose service.
F. HOUSEKEEPING 1. Compressed air from a hose must not be used in an attempt to clean a work area nor should it be used to clean machinery or parts unless specific safe proced ures are established to -.'rotect the user as well as others in the area. 2. Walkways and stairways must be kept clear of all tripping hazards such as material, tools, hoses, etc. 3. Job sites must be kept as orderly as practical dur ing the performance of the work. When a job is complet ed, the work area must be left in a neat and orderly condition.
G. LADDERS AND SCAFFOLDS 1. The following rules are to be observed when using ladders: (A) Make certain that ladders are in good condi tion and of proper length before using them. (B) Face the ladder and keep both hands free for climbing, (C) Where practical, grasp the ladder by the side rails rather than the rungs. (0) Set straight ladders so that the bottom is out from the vertical about one-fourth of the distance from the upper support to the bottom. 2. All straight ladders must be made secure at the top or must be held while in use. 3. Makeshift scaffolds, such as boxes, crates, and drums must not be used. 4. The following rules are to be observed while work ing on or over transite roofs: (A) Where a permanent platform or walkway is not provided, a temporary walkway or spread-footing
-9-
should be used to distribute the load over a large area of the transite. (B) Where it is absolutely necessary for employees to walk on transite roofs, permission must be secured from the supervisor and care must be taken to place the weight on the purlins or lap of the transite. 5. Use ladders rather than the cross braces when climb ing scaffolds. 6. The following rules apply to rolling scaffolds: (A) Rolling scaffolds of a height greater than three times the minimum base dimension must be guyed or tied off while being used. (B) All caster brakes must be applied when scaf fold is not in motion. (C) Riding rolling scaffolds is prohibited. 7. Do not attempt to use scaffolds as material hoists or for mounting derricks unless they have been desig nated for this purpose. 8. Platforms and scaffolds must be kept clear of trip ping and slipping hazards.
H. RED TAGS AND PERMITS 1. Valves, switches or any other equipment must not. be operated when RED TAGS are attached to them. These red 3" x 6" cardboard tags, bearing the word "Warning" in black letters as a heading, are attached to equipment to signify that the operation of it would be
hazardous.
Persons responsible for the equipment on which work is being done of anyone whose safety would be endang ered if the equipment were operated, may attach the red tag. When red tags are attached to equipment by per sons other than those responsible for its operation, pri or approval from the person responsible shall be obtained.
-10-
Red tags may be removed prior to operation of equip. ment only upon the authorization of the person so desig
nated on the tag. The only exception to this procedure is when the designated individual cannot be contacted. In such cases his supervisor may authorize the removal of the tag. If this is done, the supervisor must first de termine to his complete satisfaction that the equipment can be operated in a safe manner. The prompt removal of tags upon full completion of a job will help keep such cases to a minimum. Red tags may be exchanged at the end of a shift or for some other reason; but again, only the person authorized to remove the tag may do so except as stated above. 2. At the discretion of the supervisor, locks may be used on valves and switches in addition to red tags. 3. "Safe Work Permits" are designed to provide a con venient means of checking the safety of such jobs as entering closed vessels, breaking into or repairing pipe lines that have contained hazardous materials or pres sures, work involving the use of flame or spark produc ing equipment in hazardous areas and work on machin ery. These permits are to be requested and/or issued at the discretion of the departmental supervision in volved in any jobs where the "Safe Work Permit" is ap plicable.
I. ELECTRICAL 1. 32 volt transformers are to be used in connection with drop lights when working inside metallic vessels.
Exceptions to the above shall be considered when the use of 115 volts is required to accomplish the work. Special precautions shall be taken in grounding, handl ing, and inspecting electric cords, and permission shall be obtained from the supervisor before entering a ves sel. 2. In locations where grounded and polarized electri
cal receptables are not provided and there is a pos sibility that personnel may come in contact with ground or a grounded object, all portable electrical tools and equipment must be grounded before use. If three-con ductor cord with ground clip attached is used, the grounding clip must be made secure to a grounded pipe or conduit before the plug-in is made to the outlet. Dis connecting should be done in reverse order. Exceptions to the above are the operating floors of Rectifier build ings and areas listed in the Magnesium Department's safety rules. 3. When electric motor driven equipment is to be work ed on, the safety switch to the motor should be opened and "red-tagged" or the breaker lowered and "red-taggjed". Blocking starter stations open is insufficient precaution against accidental starts.
J. EXCAVATIONS AND FLOOR OPENINGS 1. Where a safety hazard would be created for the per sonnel involved, and/or others, excavations such as ditches, trenches, or bell holes, should be sloped suf ficiently to prevent cave-ins or slides, if sloping is im practical, shoring must be used in cases whenever the vertical dimension exceeds four feet. Unattended exca vations in frequently traveled areas should be barricad ed. 2. All floor or trench openings where grating or floor plates have been removed must be barricaded or marked
by suitable warning signs.
K. PRESSURE CYLINDER AND SAMPLE BOMBS 1. Compressed gas cylinders must be secured to pre vent falling when stored or being used. 2. Hoses must be disconnected from oxyacetylene torches before torches are stored in tool boxes or cabi nets. These torches and hoses must be removed from
-12-
vessels that have been vacated by personnel. 3. All compressed gas cylinders must be properly labeled as to contents. 4. Pressure cylinders must not be filled except by, or with the consent of the owner. 5. Only those who have been properly instructed may fill pressure cylinders. 6. Compressed gas cylinders designed for caps must have caps securely in place while in transit or not in use, with the exception of those on portable welding equipment
L. EMERGENCY PROCEDURE 1. In the event of an emergency such as a spill, fire or explosion in any area of the plant, ail except those charged with the responsibility of taking care of the situation must leave the area and remain at a safe dis tance until the emergency is over. Exceptions to the above may occur when a specific request for assistance is made by supervision of the plant area involved or by the Plant Protection or Fire Department. 2. The following procedure should be used to call an ambulance, report a fire, spilt of volatile materials or release of hazardous gases: Dial 666 and state that you want to report an emergency. The telephone opera tor will connect you with the emergency telephone sys tem at which time you should give your name, the exact location (building number, door, etc.) and the nature of
the emergency. The person reporting the emergency should stay on the line until sure that die message is understood and confirmed.
M. RADIATION Note: In locations where a radiation source is used or stored, regulations require that it be marked with a "Radiation Material'' sign. This sign is for the purpose
-13-
of informing anyone in the area that such material is present, and not that a safety hazard due to radiation exists. 1. Only authorized persons may enter an area marked by "Radiation Area" signs. 2. Ail areas where a radiation hazard exists must be marked conspicuously by standard signs at a safe dis tance from the source of radiation. These signs bear the radiation symbol of magenta (or purple) on a yellow background with the words "Caution-Radiation Area". 3. "Radiation Area" signs must be removed when a radiation hazard no longer exists in the affected area.
-14-
STOO14177
\a< .
PAINT DEPARTMENT
SAFETY RULES &
SAFETY REGULATIONS
JANUARY 1961
STOO14178
PAINT DEPARTMENT SAFETY RULES AND SAFE WORK PROCEDURES
Contents
Permanent Orders.............................................................. 1
Foreword................................................................................. 2
Disaster Emergency Procedures............................ 2
Safety Rules and Safe Work Procedures.... u
Respiratory Protection.............................................. 2
Tools and Equipment...................................................... General Safe Work Procedures............................ Eye & Face Protection............................................
5 7 8
Fire Protection.........................................................
Painting of Energized Electrical Equip ment..............................................................................
9 10
Scaffolds....................................................................... 11
Safe Loading of Scaffolds..................................
Rules For Scaffolding For Maintenance and Construction (booklet).........................
12
January, 1961
STOO14179
PAINT DEPARTMENT SAFETY RULES AND SAFE WORK PROCEDURES
Permanent Orders 1. Eliminate "almost-safe" practices. 2. Clean up your worx area and keep it that
way. 3. Stop looking for explanations and ex
cuses for your accidents. u. Starr, looking for causes and cures. 5. Translate the cures into action. 6. Build Safety into every step of every
Job
S. C. Cut3hall, Section Superintendent Building and Yard Maintenance
January, 1961
1
STO011t t 80
FOREWORD
.leteiy safe operation is the objective - Dow Chemical Company and it snould be -Jectlve of each employee. To achieve goal, diligent planning, proper commun,n and the complete cooperation of me on each Jc'c is required.
accidents are me result of an improper .tanding or la ok of Knowledge of condiexisting and hazards involved. These / Rules and Safe Work Procedures are to : us in working safely. Many of you articles ted in formulating seme rules .ocedures: seme were learned the hard
of rules can possibly cover all con soles that may arise from cr.anging con, ,ns. To strictly follow the rules is enough. Everyone is to be constantly on alert to detect and avoid unforeseen . i ds.
n are our rules and safe work procedures; iv and observe them. It is important that nange and improve as better and safer ...ds are learned.
. Cutshall ting & Yard Maintenance
ary, 1961
2
DISASTER EMERGENCY PROCEDUR! .o
In "he event of an explosion, fire, or a large gas release. Paint Department employees working in the area affected are to ODserve the following procedures.
If you are in the area where the disaster occurs, sr.ut down any of your equipment in operation and leave one blot/, at once.
2. Report to tr.e Paint Sncc office oy pncne as soon as possible giving your name and Icca tier..
-o not re-enter cumstances until sion.
area under any oirhcrizea by supervi-
ST00I4 181
January 1961
3
J; . ^
wlC
n 'r 3
e
i'.r. woy
-t
your
STOOI 4 I 82
materials.
3. Proper signs, barricades and/or flag men must be used when working on highways.
4. Location of safety showers and eye bath in the area of work must be known.
5. An approved type plastic safety helmet must be worn during all hours of work. Safety hats will be inspected daily by the owners. Broken brims, crowns, defect ive sweat bands, or head saddles will be repaired or the safety hat will oe re placed .
6. Operating Department safety rules and safe work procedures must be followed when working in their area. Should there be a conflict between the Paint Depart ment's safety rules and the Operating De partments rules. Supervision will confer and insure a safe condition or operation.
7. Good housekeeping will be planned at the beginning of the Job, and carefully fol lowed to the final cleanup of the Job.
January, 1961
4
ow
G8MH001S
S. Access to plpeways or other structures
must be by stationary' ladders, stairs or
oy portable ladder.
The only exception
will be when a safe Job procedures is
pprovea ana only then when safe access
an be had.
9. Necessary scaffolding must be built for all Jobs where a safe work area cannot be obtained otherwise.
January, 1961
4a
RESPIRATORY PROTECTION
Fresh air mask must be worn while blast ing. (Sand, Silicon, etc.).
Dust type respirator must be worn in areas where there is excessive dust that could be injurious.
Air supplied hood cr proper type respira tors will be worn in places wnere toxic materials are present and adequate venti lation cannot be provided.
Approved type respirators must oe worn when mere is a possibility :: inhaling over spray or vapors. A respirator must be worn while spray painting.
Only filtered air will be used in fresh air masks.
Adequate ventilation will be provided for closed tank interior work.
Men working in Chlorine Cells, Mag Cells, or on Chlorine lines must have a chemical respirator on his person.
ST00I4I84
9EI *11001S
GENERAL PLANT SAFETY RULES REVISED MAY 1, 1962
INDEX
GENERAL SAFETY RULES A. FIRST AID B. EMERGENCY PROCEDURES C. INDIVIDUAL ACTION D. VEHICLES AND TRAFFIC E. PROTECTIVE EQUIPMENT ANDCLOTHING F. MACHINERY, TOOLS, AND EQUIPMENT G. HOUSEKEEPING H. LADDERS AND SCAFFOLDS I. DANGER TAGS J. WARNING TAGS (GREEN) K. SAFE WORK PERMITS L. ELECTRICAL M. EXCAVATIONS AND FLOOROPENINGS N. PRESSURE CYLINDER ANDSAMPLEBOMBS O. GLASSWARE P. RADIATION R. SAFETY STANDARDS
PAGE i 2 3 5 6 9
tl 12 13 14 14 15 IS 16 16 17 17
soon as possible to Industrial Medicine for treat ment. The employee must notify his supervisor of the injury, as soon as practical. 2. Employees must not attempt to remove foreign par ticles from the eyes, except by washing with water. If a corrosive material (either solid, liquid or gas) gets in the eye, the eye must be washed immediate ly with running water preferably at an eyewash sta tion and the washing continued uninterrupted for at least fifteen minutes. The ambulance must be call ed so that washing of the eye can be continued enroute to the industrial Medical Department. The fifteen-minute procedure must be carried out in all eye-wash cases. 3. If corrosive chemicals come in contact with the body, the affected parts must be washed with run ning water for at least fifteen minutes. If necessary, clothing should be removed to make sure that ade quate washing is being accomplished.
B. EMERGENCY PROCEDURE
1. In the event of an emergency such as a spill, gas release, fire or explosion in any area of the plant, all except those charged with the responsibility of taking care of the situation must leave the area and remain at a safe distance until the emergency is over. Exception to the above may occur when a specific request for assistance is made by super vision of the plant area involved or by the Plant Protection or Fire Department.
2. The following procedure should be used to call an ambulance, report a fire, spill of volatile materials or release of hazardous gases; Dial 66G and state that you want to report an emergency, give your name, the exact location (building number, door, etc.,) and the nature of the emergency. The person
2
ST0 0 1UI 39
reporting the emergency should stay on the line un til sure that the message is understood and confir med. If there is a malfunction on the "666" num ber, emergency calls may be placed by dialing "0" as stated in the plant telephone directory. The Standard Emergency signals are:
Gas Re lease *
(Continuous)
This signal is sounded by the department where the release occurs. All personnel downwind of the sig nal must standby and be prepared to use necessary protective equipment, or to leave their area if nec essary.
Alert--------------------------- (series of short blasts)
This signal cancels welding permits and all per sonnel in the area where this signal is given must be prepared to use proper protective equipment if required to stay, to evacuate if ordered, or return to work at the All Clear signal.
Evacuate----- ------- ------- (series of 3 short blasts)
Upon hearing this signal in your work area, leave the area according to your Unit Emergency Plan.
After evacuation you should remain clear of the area, but ready to return when the All Clear signal is given.
All Clear-
-(series of 3 long blasts)
When this signal is given, return to your work area as soon as possible. If operating a motor vehicle in an area where a Gas Release signal is given, turn off the engine, get out of the vehicle, and be prepared to leave the area if necessary. Never drive a motor vehicle into an area where there is a gas release.
3
Always be alert for the standard emergency signals given above.
C. INDIVIDUAL ACTION
An individual's actions must constantly reflect safety con sciousness. Always work with safety for yourself and your feliow employee in mind.
1. All employees are expected to know and abide by their departments' safety rules. They must familiar ize themselves with, and be governed by the writ ten safety rules of any department they might enter.
2. Horse-play in any form must not be engaged in by employees in the plant or while on duty.
3. Running in the plant must be avoided except in case of an emergency.
4. Employees must not climb through, under, over or between railroad cars except in performance of as signed duties.
5. Compressed gases, including air, must not be used for cleaning of clothes or the body.
6. Employees must not make inoperative, as a matter of convenience, such safety devices as relief val ves, electrical and mechanical interlocks, or guards.
7. Unsafe shortcuts, such as walking across ditches or pipelines, and cutting corners to save a few steps, must be avoided.
8. Before beginning work in areas where contact with corrosive chemicals is possible, employees must familiarize themselves with the location of the near est safety shower, eye bath, and telephone, and know the location of emergency equipment such as gas masks, fire extinguishers and fire blankets in the area in which they work.
9. All containers such as bottles, jugs, or cans of chemicals must be properly labeled.
4
10. Smoking is strictly prohibited in the plant in those areas posted with "No Smoking" signs, except in
* smoke shelters at designated times. 11. Maintenance personnel must report to the operating
supervision before beginning work in a production plant area on a non-routine job, and daily thereafter until the job is completed. Upon completion of the work, operating supervision must be notified that they are leaving the area. 12. Flammable materials must not be dumped into sew ers without permission of the supervisor. 13. Every employee must insist on the observance of safe practices of fellow workers.
D. VEHICLES AND TRAFFIC
1. Pedestrian paths and walkways must be used when ever provided. In their absence, employees using streets and roadways must walk on the left side, facing approaching traffic.
2. The driver of a company vehicle is entrusted with the responsibility for its proper use. Any malfunc tion of brakes, lights or horn, or fumes in the cab or any unsafe condition must be reported to the Garage at once, and the vehicle repaired before any further use is permitted.
3. Drivers of plant vehicles must keep on roadways designated for such traffic as much as possible.
4. All traffic signs in the plant must be obeyed. Em ergency vehicles on call may be exempt, but driv ers of the same shall be responsible for driving with due regard for the safety of others.
5. The speed limit in the plant is 30 miles per hour for cars and trucks and 20 miles per hour for scoot ers, unless other wise designated by signs. The removal of, altering or otherwise tampering with the
carburetor or governor settings on motor scooters to increase the speed is prohibited. 6. The maximum number of people who may ride in a pick-up truck is three in the cab and six seated on the pick-up bed, or on approved "built-in" seats. Under no circumstances should arms or legs hang outside the vehicle cab or bed. 7. Employees, when riding on open type trucks, must not stand up or hang their feet over the sides. 8. Hauled material that overhangs the sides or ends of trucks must be red flagged at the extent of the overhang. 9. Personnel newly authorized to operate motor scoot ers must be given proper instructions in their safe operation.
10. The load capacity for truckster model scooters is 500 pounds. Not more than two passengers and the driver may ride in truckster model scooters, and then only when an approved seating arrangement is provided by the Garage.
11. Motor scooter engines must not be left running while scooter is unattended.
12. Night operation of bicycles, scooters and powerbuggies without lights and reflectors is prohibited.
13. Passengers standing on plant route busses must stay to the rear of the front row of passenger seats, and passengers must not attempt to get on or off busses while they are in motion.
14. Smoking is not permitted in vehicles in designated no smoking areas.
15. Gasoline tanks on motorized equipment must not be filled while the engine is running.
E. PROTECTIVE EQUIPMENT AND CLOTHING
Protective equipment is provided and specified in these and departmental rules.This equipment must be periodical
STOO14143
ly checked to assure good working order. 1. When entering any designated compulsory eye pro tection area, all persons are required to wear eye protection as specifically approved for that area. 2. Proper type goggles must be worn when chipping, grinding, buffing, cleaning welds, loading or un loading material, or any similar operation where flying particles constitute an eye hazard. 3. Departmentslly-approved eye protection must be worn by employees when transferring corrosive ma terials (such as acid, caustic, etc.,) from one con tainer to another by pouring and when taking pro cess samples of such materials. 4. Chemical goggles must be worn in areas where cor rosive materials may be splashed or spilled. In ad dition, adequate protective clothing, such as face shields, slicker suits, rubber gloves and rubber boots must be worn when breaking into, or discon necting, piping, pumps, vessels, or related equip ment that contains, has contained, or may contain acids, caustic, or other corrosive materials. 5. Employees working with or around electric arc weld ing or cutting must wear approved eye protection, and provide adequate ventilation. 6. Employees should wear proper eye protection under the following conditions:
(a) When handling carboys or glass bottles of cor rosive liquids.
(b) When a high wind is blowing. (c) When riding motor scooters or open trucks on
plant roadways. 7. All employees subject to any hazardous exposure,
including dust, chemicals, or toxic irritants, must wear adequate protective equipment approved by their supervisor and the Safety Department, such as
face shields,head protection, rubber jackets, slick* er suits, coveralls, fire resistant clothing, protect* ive sleeves, spats, gloves, aprons, protective foot* wear, respirators and gas masks. Company-furnish ed clothing and protective equipment must not be altered. 8. All employees must wear personal clothing that is safe and proper for their job. Life jackets, and/or life belts, must be worn as required by .department rules. In no case shall an employee in the plant work in an undershirt, shorts only, or stripped to the waist. 9. Metal safety hats are prohibited in areas that are electrically hazardous. An approved safety hat must be worn by all employees while in areas where there is a hazard of falling objects. 10. Adequate ventilation must be maintained when us ing solvents. If ventilation is inadequate, then res piratory protection must be worn. 11. Safety belts, with lifelines attached, are to be worn by employees when performing work in elevated positions where the use of scaffolds or ladders is impractical and where a slip might result in a seri ous accident. 12. All full-face respiratory protective equipment must be sent to the Fire Department at least annually for
checking. 13. In the event it becomes necessary to enter a vessel
that may not be completely free of hazardous con tents, a safety belt and lifeline must be worn in addition to other protective equipment needed.Safe ty belts and lifelines must be worn by those enter ing vessels whenever it is deemed advisable by supervision.
8
1
*1*1f *11001s
INERY, TOOLS, AND EQUIPMENT
achines must have all guards in place before opfated, unless the specific job is approved by the tlpervisor. When permission is given by the super
visor to remove a guard from a machine or tool, the pervisor must instruct the employee on special recautions to be taken while operating the machine `or tool with the guard removed. All pedestal and bench grinders and buffers must have a satisfactory guard over the wheel. Portable :grinders and buffers must have a satisfactory guard
over the wheel except in cases where special con ditions make the use of a guard impractical and the employee's supervisor has approved its use without a guard. The guards on wire buffing wheels mount ed on pedestal or bench grinders should be cut back at the bottom about 30 degrees from the verti cal center line of the guard. Grinding on the side of emery wheels must be done only on wheels that are designed for this purpose. - 4. Tool rests on grinders must be set not more than 1/8 inch from the wheel. Buffers are not to be op erated with tool rests.
5. Gloves must not be worn while using grinders, buf fers, or drill presses unless permission to do so is secured in advance from the supervisor.
6. Neckties,.loose clothing and jewelry, such as tie chains, watch chains, and rings, must not be worn around moving machinery.
7. Moving machinery and process equipment in service must be shut down before adjustments or repairs are made, except as follows: If it is not feasible to shut the equipment down before performing work upon it, then it is necesarry for department super vision to:
9
(a) Determine for each item of such equipment what jobs must be performed, with a listing of these jobs made for the use and information of the workmen and their supervisors. Any non* listed jobs of any nature are not to be done.
(b) Prepare a detailed safe job procedure for each listed permitted job, and also a list of person nel authorized to perform these jobs.
8. Vessels to be entered, or worked upon, must be made safe for personnel by such means as dis-connecting, blinding, or double-block and bleed. If such precautions are impractical, a detailed pro cedure for performing the work in a safe manner must be prescribed by supervision.
9. The use of non-ferrous tools is to be given con sideration on jobs and in areas where an explosion or fire hazard exists.
10. Tools, material or equipment must not be intention ally dropped or thrown from a higher to a lower level unless adequate precautions have been taken to make sure that no injury to persons or damage to equipment will occur.
11. Defective tools are to be tagged with a "Defective Tool Tag'*, and returned to the Tool Room for re pairs.
12. Air pressure on pneumatic tools must be bled down before disconnecting them from the air supply.
13. Spring-loaded snap.on "Cleco" quick hose connec tions must be reserved for use on air and water ser vice only. A part of the "Cleco" connector must not be left connected to a process line or equip ment.
14. Unmarked, or unlabeled, lines must not be used without approval of the owner. Service Lines com monly used must be identified on the valve end. In
10
addition, all methane lines one inch and smaller must be identified on the valve end, and approval must be obtained before use. 15. "Boss-type" hammer union connectors must be us ed on steam hose service. 16. All power transmission couplings must be guarded unless the design or location is such that the chance of personal contact is extremely remote. 17. Employees must not ride a load that is being hand led by a crane. The riding of crane slings is pro hibited, except where a bosuns' chair is provided. 18. Vessels moved to the shops and salvage must be cleaned whenever practical, and tagged as to con dition and previous contents before they can be moved from one location to another. See Safety Standard #1.
G. HOUSEKEEPING
1. Compressed air from a hose must not be used in an attempt to clean a work area nor should it be used to clean machinery or parts unless specific safe procedures are established to protect the user as well as others in the area.
2. Walkways and stairways must be kept clear of all tripping hazards such as material, tools, hoses, etc,.
3. Job sites must be kept orderly during the perfor mance of the work. When a job is completed, the work area must be left in a neat and orderly con dition.
4. It is the responsibility of each employee to help keep lunch rooms, change rooms, and toilet facili
ties orderly, clean and sanitary. 5. Empty soft drink bottles must be replaced in the
racks provided.
H. LADDERS AND SCAFFOLDS
1. The following rules are to be observed when using ladders:
(a) Make certain that ladders are in good condition and of proper length before using them.
(b) Face the ladder and keep both hands free for climbing.
(c) Where practical, grasp the ladder by the siderails, rather than the rungs.
(dl Set straight ladders so that the bottom is out from the vertical about one-fourth of the dis tance from the upper support to the bottom.
(e) Employees must not stand on the top step of a stepladder.
2. All straight ladders must be made secure at the top or must be held at ground level while in use.
3. Makeshift scaffolds, such as boxes, crates, and drums must not be used.
4. The following rules are to be observed while work ing on or over transite roofs: (a) Employees must not walk, drop or jump onto a transite roof.
(b^ Where a permanent platform or walkway is not provided, a temporary walkway or spread-foot ing should be used to distribute the load over a large area of the transite.
5. Ladders must be provided on scaffolds, and cross braces are not to be used for climbing.
6. The following rules apply to rolling scaffolds: (a) All caster brakes must be applied when scaf fold is not in motion. (b) Riding rolling scaffolds is prohibited.
7. Any scaffold of a height greater than three times the minimum base dimension must be guyed or tied off during use.
12
8. Do not attempt to use scaffolds as material hoists or for mounting derricks unless they have been de signed for this purpose.
9. Platforms and scaffolds must be kept clear of trip ping and slipping hazards.
10. Permanent ladders on towers or vessels are not to be blocked byscaffoiding inserted through the cage.
DANGER TAGS
1. To insure that equipment is not operated while it is being worked on, Danger Tags are attached to the controls so that personnel will know not to use them. These tags must be used to protect personnel exposed to the hazards of the equipment involved and must be respected by all personnel. The per sonnel responsible for the operation of equipment must clear and tag the equipment; any personnel whose safety could be endangered while working on this equipment may affix their tag. Violation of Danger Tag Rules must result in disciplinary ac tion up to and including discharge.
2. No control such as a valve, switch, clutch, etc., is to be operated by anyone while a Danger Tag is attached. If a control must be operated intermittent ly such as for testing equipment, the Danger Tag must be properly cleared and removed before each operation.
3. Whenever the operation or use of any equipment may endanger anyone, a request must be made to supervision of the group which operates the equip ment to clear and tag the equipment. '`Clearing" means making the equipment inoperable and safe for others to work on. The authority to clear and tag equipment may be delegated by this supervision to qualified personnel after supervision has assured themselves that the person delegated can clear the
13
particular job involved properly. 4. After the group which operates the equipment has
cleared and tagged the equipment, each worker or group of workers who may be exposed to the haz ards may tag the equipment for their protection.
When Danger Tags are attached to equipment by persons other than those responsible for its opera tion, prior approval from the person responsible shall be obtained. 5. As the individual jobs have been completed each worker or group of workers must remove their tags immediately. 6. The group responsible for the equipment must place their tag first and remove their tags last. 7. Danger Tags may be removed only upon authoriza tion of the person designated on the tag. The su pervisor of any preson who fails to remove a Red "Danger" Tag when a job has been completed may authorize the removal of the tag after he has de termined to his compiete satisfaction that the equip ment can be operated in a safe manner. 8. At the discretion of the supervisor, locks may be used on valves and switches in addition to, but not replacing, Danger Tags.
J. WARNING TAGS (grn)
1. When it is necessary to convey instructions or in formation prior to operation of equipment controls, Green "Warning" Tags are to be attached to the controls.
2. Green "Warning" Tags should be removed when conditions set forth on the tag have been met.
K. SAFE WORK PERMITS
1. "Safe Work Permits" are designed to provide a con venient means of checking at the job site the safe-
14
2.1
S T 00IM 50
STOOI4I5I
ty of such jobs as entering closed vessels, break* ing into or repairing pipelines that have contained hazardous materials or pressures, work involving the use of flame or spark producing equipment in hazardous areas and work on machinery. These permits are to be requested and/or issued at the discretion of the supervision involved in any jobs where the "Safe Work Permit" is applicable. A Safe Work Permit must be re-issued for a job if there is evidence that conditions have changed subsequent to the issuance of the original Safe Work Permit.
L. ELECTRICAL
1. 32 Volt transformers are to be used in connection with drop lights when working inside metallic ves sels. Exceptions to the above shall be considered when the use of 115 volts is required to accomplish the work. Special precautions shall be taken in grounding, handling, and inspecting electric cords, and permission shall be obtained from the supervi sor before entering a vessel.
EXCAVATIONS AND FLOOR OPENINGS
1. Where a safety hazard would be created for the personnel involved,and/or others,excavations such as ditches, trenches, or bell holes, should be sloped sufficiently to prevent cave-ins or slides. If sloping is impractical, shoring must be used in cases whenever the vertical dimension exceeds four feet. All excavations must be barricaded by the persons performing the work,
ft 2. All floor or trench openings where grating or floor plates have been removed must be barricaded or marked by suitable warning signs by the persons performing the work.
15
#
N. PRESSURE CYLINDERS & PRESSURE SAMPLE CON. TAINERS
Each individual responsible for filling, handling, & storage of Pressure Cylinders & Pressure Sample Containers must be familiar and comply with the requirements of Safety Standard #9 Compressed Gas Cylinders and Pressure Sam ple Containers.
1. Hoses must be disconnected from welding and cut ting torches before torches are stored in toolboxes or cabinets. Torches and hoses must be removed from vessels that have been vacated by personnel.
2. The supply of oxygen and fuel to torches that are left unattended must be shut off at the cylinder valves when a job has been completed and the reg ulators and hoses must be depressured.
O. GLASSWARE
1. All broken glassware must be repaired or discarded. 2. Do not heat glass bottles on a hot plate without
precaution against breakage.
3. No pressure systems are to be used with glass with out approval of personnel completely familiar with the possible hazards.
4. Hand protection is required when force is applied to glass, such as in inserting or removing glass tubing from stoppers or in breaking off at a file mark.
5. Broken glass should be removed by use of broom and dust pan and placed in dempster box or suit ably marked container. In no case place broken
glass in waste baskets. 6. To prevent breakage in transit, all glass contain
ers shall be properly crated or otherwise suitably packaged before being transported from the immedi ate area in which they'are being used or stored. 7. All glass bottles with capacity on one gallon oi
16
more,
iteria
regard
1 r
P. RAD
Note: It
STOO14152
2. All areas where a radiation hazard exists must be marked conspicousiy by standard signs at a safe distance from the source of radiation. These signs bear the radiation symbol of magenta (or purple) on a yellow background with the words "Caution - Ra diation Area."
3. "Radiation Area" signs must be removed when a radiation hazard no longer exists in the affected area.
17
ST0014154
R. TEXAS DIVISION SAFETY STANDARDS
1. Plant Shipping Tags 2. Pressure Gauge Mountings 3. Isolation Motor Circuits for Work on Motors & Motor
driven Equipment. 4. Gas Cylinder-Type Pressure Regulators, Gauges &
connections. 5. Railroad Derails and Blue Warning Flags 6. Grounding of Portable Electrically Operated Equip
ment and Tools 7. Electrical Bonding and Grounding 8. Procedure for the Disposal of Waste Materials in
Drums and other Containers. 9. Compressed Gas Cylinders and Pressure Sample
Containers 10. Acetone used in Laboratories. 11. Inspection of hand operated hoisting equipment.
18
THE row CHEMICAL COMPANY
Texas Division GENERAL PLANT STANDARDS
<-
INSOLATION SPEC. 8-627
Dated 12-14-62 Page 1 of 5
INSULATION FOR
PERSONNEL PROTECTION
PIPE AND FITTINGS
1. Insulation Material
I.I Pipe
Tie insulation material for piping shall be one, or more, of the following, or Dew-approved equal:
1.1.1 "Hinged" type sectional fiber glass insulation, 3 foot or 6 foot lengths, suitable for continuous service at 350 F., such a3:
Guatin-Bacon Snap-On, Johns-Manville Micro-Lok, or Carey Thermoglas;
> For Class G-P only. From l40F. to 350 F.
Note: Plain fiber glass pipe insulation, or insulation with factory applied Jacket may be used. See Sections 4 and 3 for type of Jacket required.
1.1.2 1.1.3
Mineral wool industrial pipe insulation, standard N
lengths, fabricated to fit pipe, such as:
For Classes
Baldwin-Ehret-Hill #101 pipe Insulation, or C-P, D-P,
SE-P, F-P,
Carey mineral wool industrial pipe insula and G-P.
tion; or
From 1^F.
to 1000 F.
Insulating materials specified in Dov Standard
8-601, page 3, inay be used.
J
1.2 Pipe Fittings and Valves
Note: The insulation shall be omitted from all valves and all flanges for Class G-P insulation.
The insulation material for pipe fittings and valves shall be the same material specified for piping or the material specified for vessels and equipment (See Dow Standard 8-647)
a z h n e s o is
All in/<xmatton hereon is the confidential property ofThe Dour Chemical Compmtyf Texas Division.
Suhiect to retien on demand and must not he made titJiltr re
umhr*4tr umtten sssnws/.
2. Insulation Thickness
SPEC. 8-627 Page a of 5
)
1
11
1d
NOMINAL INSULATION THICKNESS
Temperature
of Pipe or Equipment 1" aid.
NOMINAL PIPE SIZE
Over 24" and
Under l li 2 3 4 5 6 8 10 12 ik 16 18 20 24 Flat Surf
C-P
1000F. to 800F.
iin J 3"
I 800F. to
; D-P
700OF.
ii"
2 2"
js-p . 700F. to 6oof.
i
; F-? i
6oof. to 350F.
1g-p 1
350F. to l40F.
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2" 1" 1"
1. For temperatures 800F. and over, insulation shall be applied in double-layer
construction with staggered joints, or in single-layer construction with Dewapproved xpansion joints.
2. For temperatures 350 to 800F. (Class D-P, E-P, and F-P) insulation shall be applied in single-layer construction with Dow-approved expansion joints.
O
General Plant Standards
Insulation Spec. 8-627 Dated 12-14-62 Page 3 of 5
3. Application
3.1 Pipe
3*1.1 Fiber Glass, Plain
All end joints shall he tightly butted and the single longi tudinal seam shall be held together with- copper clad outward clinch insulation staples, 4 staples per 3-foot section.
No bands are required except over asbestos felt jacket. See Section 5*
3.1.2 Fiber Glass with 6-ounce Canvas Jacket
Apply the same as plain fiber glass. Paste down all canvas laps with white adhesive such as Foster's Lagfas 81-42W, Airbol, or Dow-approved equal.
3-1.3 Fiber Glass with 55-pound Asbestos Jacket, White Exterior
Apply the same as plain fiber glass. Seal asbestos laps with asphalt seam sealer.
Apply bands over the asbestos jacket as specified in Section 5* 3.1.4 Mineral Wool
Butt end joints. Secure longitudinal seems with lead vires furnished with the insulation, or with, 16 gage 302 or 304 stain less steel wires on 9" centers.
3.2 Fittings, Valves, and Flanges
3.2.1
The insulation shall be stopped short of all flanges and valves on Class G-P insulation. The ends of the insulation shall be tr beveled to permit removal of the flange bolts. Flanges and valves with insulation hotter than Class G-P shall be insulated.
3.2.2
The insulation for fittings and the body of valves (when insulated) on pipe 2" and smaller shall consist of a built-up layer of insulating cement or other material suitable for the temperatures involved. Total thickness of insulation to equal that on adjoining pipe.
3.2.3 Fittings on piping 2 l/2" and larger and the bodies of the flanged valves (when insulated) shall be insulated with blanket or sectional insulation to a thickness equal to that on adjacent piping.
3.2.4 Flanges (when insulated) shall be covered with sectional pipe or blanket insulation to a thickness equal to that of the insulation on the adjacent piping.
3*2.5 The insulation on the body of 2 l/2" and larger fittings and valves and on all flanges shall be securely wired or banded in
All information hereon <s the Confidential property of The Dout Chrrmtrmi Company, Te*J< Division.
?uAi/rf fn en ^ *>t wxit nrtt *++ -- *
J
SPEC. 8-627 Page 4 of 5
place. On flanges, the Insulation shall he of such length as to extend not less than 2" or a distance equal to the insulation thickness, whichever is greater, over the adjacent pipe insulation on each side of the flange. The total thickness cf the insulation shall he equal to that on the adjacent piping.
3.3 Bends
3.3*1 Bends shall he covered by mitering sectional insulation, or hy using blanket insulation.
It-. Finish Indoor
4.1 Pipe
it-. 1.1
The finish for pipes indoors in all areas, except in production plants, shall he 6-ounce white canvas lapped at least 2" at all joints and pasted over the insulation with white adhesive such as Foster's Lagfas 31-42W, Airhol, or Dow-approved equal. After the canvas is in place, apply a full coat of white adhesive.
Pipe furnished with 6-ounce canvas jacket will require sealing of the seams (See Section 3*1.2), followed hy one full coat of white adhesive, Foster's 81-42M, Airbol, or Dew-approved equal.
4.2 Fittings, Valves, Flanges, and Bends
4.2.1
These items shall he finished with a two-coat application cf a white FVA resin emulsion; such as Foster's 31-99 Sealfas Mastic car Dow-approved equal; reinforced with a layer of open-weave glass cloth. Lap all edges at least 2". All voids and pinholes must he covered, leaving a smooth, neat finish.
5 Finish Outdoor
5.1 Pipe
5.1.1
All piping outdoor, or otherwise exposed to the weather, shall be finished with a waterproof jacket of asbestos roofing felt, white one side, tightly wrapped on, with a cold Beal of adhesive applied evenly over the entire surface of all lap joints. The weight of asbestos felt shall he 50 to 55 pounds/lOO square foot. All Joints shall he lapped as follows:
Insulated Outside Diameter
Minimum Joint Lap
Less than 8" 8" and larger
2" 3"
On horizontal pipes, the seams of the waterproof Jacket shall he placed at the side of the pipe with the lap turned down in order to shed water.
Secure waterproof jackets with 302 or 304 stainless steel hands spaced a maximum of 10" from center to center of hands, with one
ST0534425
)
General Plant Standards
Insulation Spec. 8-627 Dated 12-14-62 Pag- 5 of 5
band not more than 3" from the end of each Jacket. Bands shall be 3/8" wide by .015" thick for all sizes of pipe.
5.2 Fittings, Valves, Flanges and Bends
3.2.1 Finish the same as indoor. See Section 4.2.
6. References
6.1 Dow Standards:
Standard No.
Title
8-647
Insulation of Personnel Protection - Vessels and Equipment.
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R. c. Middleton
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10/26/64
The question.concerning asbest03i3 had to do with 3awing Transite. Although the dust from such an operation will probably contain respirable particles of asbestos it is highly unlikely that enough exposure would exi3t in the use of Transite to represent a real hazard.
It wa3 explained to the men that in using the epoxy resins it i3 necessary that contact with the skin does not occur. We explained that the seriousness of the ra3h steins from the fact that exposures which appear to be acceptable can result in sensitization and that once a person is sensitized he can no longer work With the epoxies.
We explained that the plant air was free of carbon monoxide and mercury and explained our plan for checking the air for oil mist and other particulate material, There was some discussion concern* ling the use of an oil trap in the air line. The equipment used in Midland was shown.
The men reported that those who had been involved in sand blasting equipmeifc in the Catalyst Plant had been plagued with rashes which they associated with nickel salts. We stated that there is such.a thing as dermatitis due to nickel and that surely the appearance " of rashes associated with such contact indicated the need for.keeping the material off the skin and for removing it if any contact should occur.
I hope you will forgive the tardiness of this report. My only ex cuse is that entirely too many demands have been placed on my time since last I saw you.
Best personal regards.
tST000001 9
H. R. Hoyle Biochemical Research laboratory 1701 Building
HRHrreh
Enc.
F1 6
OFFICE COPY
i Biochemical Research Laboratory
The Dow Chemical Company
i */OO
EXPOSURE TO PINE DUSTS ENCOUNTERED
Pile: T2.1-3-1
i BY WORKERS CUTTING VARIOUS TYPES OP PIPE COVERING MATERIAL
Date: July 21, 1965 By: E. J. Schneider
i Signed
JjL
Date
7/l3- / (qS
----------------------
l Checked 14
Date 7- i 2
I DOW CONFIDENTIAL s
I A question was raised by shop personnel after reading an
article of the health hazards associated with exposure to asbestos.
L Is there a health hazard from asbestos in cutting various types of
pipe covering material used at Dow Corning? The Environmental
I Research Laboratory was asked to evaluate the exposures to the
fine dusts encountered by workers cutting the pipe covering material and to determine the possible health hazard.
CONCLUSIONS Concentrations of total dust in excess of acceptable levels can be encountered by workers cutting pipe covering material both by nand and in using a table 3aw.
A total dust count or the number of particles per million cubic feet of air also exceeds acceptable levels at times.
C
C
( <
C C ( (
The amount of asbestos fibers of significant length found within the dust exceeds 25 per cent cf the fiber content,
DAK 01161
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Biochemical Research laboratory T2.1-3-1
Page 2
however, fibers constitute only 10 per cent of the total i dust. The possibility that Dow Corning workers are being
exposed to excessive amounts of asbestos fibers within the important fiber lengths (20-50 microns) 13 unlikely, hovever. It is advisable and prudent to have workers wear respiratory protection while cutting pipe covering material. This is especially true when using a table saw.
4. No one type of pipe covering material was found to have a significantly greater amount of asbestos fibers than the others. The Phillip Carey Pibercel material does produce considerable more fine dust than the others when cut.
5 IUUUUbby
ASBESTOS In reviewing the literature^ it is learned that the
most common form of asbestos, is known as chrysotile, a hydrous
magnesium silicate containing from 12.5 to 14 per cent water of
crystallization. There is another form of asbestos derived from
amphibole which occurs as a variety of minerals consisting of
iron, calcium and magnesium silicates with little water of con
stitution. ?hl3 latter type of asbestos consists of shorter
fibers but i3 more 3table chemically than chrysotile and more
resistant to acids and heat.
DAK 01162
<) Industrial Toxicology - L. T. Fairnall, pp. 19-21, 1957 <
Blocnemical Researcn Laboratory T2.1-3-1
Page ?
ST0000570
It la this latter type of asbestos which 13 thought to be uaed in the varloua pipe covering material te3ted becauae x-ray diffraction analysis of the materials snowed them to con tain tobermorlte, a calcium silicate form of asbestos.
The inhalation of asbestos dust produces a condition known as aabestosis. Asbestos is the only silicate apart from talc and mica which does not contain free silica and yet produces pulmonary lung fibrottic changes. The fibrogenic action differs from silica in that the effects are produced only' by long asbestos fibers. Very short fibers appear to have little or no effect. The long fibers apparently block the finer bronchioles of the lungs and produce fibrotlc changes as a result of irritation.
The literature^ states that in the case of asoestosis
unlike silicosis fibrosis does not progress indefinitely after cessation of exposure. It further states that in order to produce aabestosis in workers exposures must be in excess of 5 millions particles^cubic foot for extended periods (greater than 10 years) and the fibers in the range of 10-250 p in length. Some authorities Indicated that only those asbestos fibers in the 20-50 p range ar significant for producing asbestosi3.
The present Industrial Hygiene Stanaaros state that for control the number of particles of a3Destos dust be Kept be Low
^Industrial Hygiene and Toxicology - FranK PP o^Q-599.1
id tty, Vol. I, DAK 01163
Biocnemicai hesearcn Laboratory
T2.1-3-1 rage 4
5 rapcf and that for nusiance. dusts of any type the number of .particles must be below 50 mpcf or 15 mg3 total dust per cubic foot of .ii..
PRESENTATION OK DATA
Karij
j.960 a vi3it was made to Dow Corning to make
measurement.* m >.re duat exposures encountered by workers cutting
pipe coverin>.
lal. In a small room (approximately 10' x i5')
adjacent to u.i t ..1 ocnter snop building 409 a worker was asked to
hand saw sever. '.cces of the various types of pipe covering
' material used at Dow Corning. Air samples were collected in his
breathing zone while sawing the materials. Analyses were made
for both total au... ana the number of particles of dust In tne contaminated air
In another ....ail room (approximately 8' x o') part of tne
pipe shop building 31o tests were repeated for two different pipe
covering material- .mile a worker used a table saw to cut tne
materials.
At botr. . . ---ns cnly general ventilation was usen witn
no local exnaust oj-.u.u for dust collection.
The air sampler collected for total du3t louu w-^re nv:r
sent to Dow laboratories for x-ray diffraction analysis in-: ..vn
microscopic evaluation.
Table 1 snows a summary of tne results cotainea fur ere
d
air samples by the various analytical technique
DAK 01164
ST000057I
TCE'-SD PY *CSPE3S C X T IV 3 VARIOUS TYPES CP PIPE C0VE3IN0 MATERIALS
Vino o~l
ST0000572
Blocnemlcal Research Laboratory T2.1-3-l Page 6
The total dust exposure is not excessive in hand sawing mostiOf the types of pipe covering material, however, sawing the Phillip Carey Fibercei material does produce a very fine dust and does produce excessive concentrations of dust.
The use of the table saw as would be exoected produces very large quantities of dust even for a not too dusty material 3uch as the Baldwin Ehret Hill Unlbe3tos.
The dust count in millions of particles per cubic foot did exceed in all cases the 5 mpcf Industrial Hygiene Standard for asbestos. However, because asbestos fibers represent approxi mately 10% of the total dust and because only approximately 25% of the fibers are considered of . significant size, it is doubtful that workers encounter a health hazard in their normal work load of cutting pipe covering material.
The practice of using a table saw either within a shop building or out in the field should not be continued without adequate control of the dust or the use of respiratory devices. It also seems advisable to encourage workers to wear respiratory orocectlon when hand sawing material. Anv Bureau of Standards approved dust respirator thou la prove adequate to filter out tne a3besco3 fibers.
DAK 01166
ST0000573
Biochemical Research Laboratory TC. 1-3-1 Page 7
UNIT INDEX
' Measurements were made of the du3t exposures encountered by workers cutting pipe covering material, Pioe Shop Department, Dow Coming Corporation, Midland, Michigan. Concentrations of total dust In excess of acceptable levels can be produced both in hand sawing and n the use of a table saw. The amount of asbestos fibers found did r.nt constitute a health hazard. Respiratory protection Is recommended tc be worn when cutting pipe' covering material.
DISTRIBUTION
Jack Quinn, Safety Department, Dow Corning Corporation H. H. Gay, M.D., Medical Department, 607 Building A. Wilson, Safety Department, 401 Building ?. C. Middleton, Safety Department, Ludington Division
W. Snodgrass, Maint. Service Admin., 49 Building (7/9/71)
(4)
i/snnnnis
DAK 01167
PHOTOMICROGRAPHY
ALS *37 5
Phocomicrographs were prepared employing Bright field
y
Phase Contrast ________ Oblique Transmitted Light ___________
Dark field Polarised Light Oblique Reflected Light
technlqu
to show ________ particles an-i Hber3
Label Data for
8 x 10 prints contact prints
Negative #
L5-525 L5-526
Sample
Latex Filter // 2 Latex Filter // 8
Microscopy
B. F. B. F.
Magnif
300X 300X
DAK 01168
THI DOW CHfMICAL COMPANY CHIMICAL PHYSICS RKSIARCH LAIORATORY
'1*0*f nuhC 168499
E. J. Schneider IMiCCT
1 Biochom Res. Lab.
MtfMttC M'WMI 1701
X-ray Diffraction Analysis of dust samples from cutting pipe
covering at Dow Corning
CftARCf MO.
_ 1219-26 ou ifctmo
2-2-65
UCMCO
H. Rinn OAir 2-11-65
# 1 (.0001 g)
Tobermorite - XCaO*Si03yH20 where x varies between 0.8 and 1.5 and y between 0.5 and 2.0
#2 (>.0001 g) *3 (.0004 g)
Same as #1 Same as #1
*4 (.0020 g)
Same as #1
#5 (.0008 g)
This sample gave a very weak pattern of hydromagnesite - 3MgC03>MgOH)3*3Ha0. There could be amorphous material present.
#6 (<.0001 g)
Tobermorite and some calcite. Pattern quite weak, probably because of small sample.
* #7 (.0052 g) #8 (.0036 g) No quartz was
Mainly tobermorite with 10-20% talcite - CaC03. Mainly tobermorite with 5-10% calcite.
Rote on appearance of tobermorite - from Crystallographic Data for the Calcium Silicates by Heller and Taylor.
Natural mineral from Ballycraigy: minute, radiating agregates of fibers with distinctive silky lustre on the cleavage faces. Natural mineral from Mull or Skye: fine geared aggregates of minute, birefringent crystals.
Synthetic material: minute irregular crystals, birefringent.
HWR:abj 2-11-65 3
'** ""'ll II |. -
DAK 01169
1/.S00001S
THE DCW CHEMICAL COMPANY Texas Division
GENERAL PLANT STANDARDS
PREFACE TO INSULATION STANDARD SPECIFICATIONS Revised October 4, 1965
56-201
4-25-66 Paje 1 of 9
ST0402983
A. COLD INSULATION
Cold insulation in the standard specifications is designed for nonsweating when the ambient temperature is 90 F, the relative humidity is 85% and the wind velocity is 0 mph. The dew point under these conditions is 85 F. The heat gain under the same conditions ranges from 4.6 to 7 Btu per hour per square foot of insulation. Maximum heat gain for flat surfaces and cylindrical vessels under the above conditions is 7 Btu per hour per square foot.
The year round average heat gain in the Gulf Coast area is less than that given above because the average temperature is less than 90 F. It is even less further north.
An additional insulation thickness of 50% only reduces the maximum heat gain, under the above conditions, to around 4.7 Btu per hour per square foot, or to 41,172 Btu per square foot per year.
If 25% less insulation is used than is specified in the standards, the maximum additional heat gain, under the above conditions, is approximately 2.3 Btu per hour per square foot, or 20,148 Btu per square foot per year.
For critical process temperatures, insulation thicknesses greater chan those specified in the standards may be required.
For noncritical temperatures and where surface sweating is not objectionable, thinner insulation may be used. In some cases, insulation may be eliminated.
Vapor Barrier (Essential for All Cold Insulation)
Definitions:
Vapor Barrier. A vapor brv.-ier is a material having a high resistance to the passage of water vapor It should have a perm rating of not more than 0.1 perms for the thickness used.
Perm. A perm-inch or one perm equals one grain of water vapor per hour per square foot per 1" thickness (except where noted otherwise) per 1" difference in mercury vapor pressure.
A vapor barrier should be used on all cold insulation that allows migration of water vapor. `This includes Styrofoam and Thurane which have perm ratings of l to 2 perm-inch, and 2.5 perm-inch respectively.
Why Vapor Barrier is Necessary:
Water vapor acts like a gas. It can pass through any substance that is not impermeable The force that drives it through insulating material is the difference in vapor pressure between the warm side and the cold side of the insulation.
THE DOW CHEMICAL COMPANY Texas Division
GENERAL PLANT STANDARDS
56-201
4-25-66 Page 2 of 9'
ST04G29841
Water vapor will always flow from a higher partial pressure area to a lower partial pressure area--never the reverse. The vapor pressure is a function of temperature--the higher the temperature, the higher the-vapor pressure. (See Vapor Pressure Table, Page 3.) The insulated "cold" surface normally has a lower temperature than ambient; therefore, the partial vapor pressure gradient decreases from the outside of the insulation inward to the cold surface, which causes the flow of water vapor in this same direction. As the vapor flows toward the "cold" surface, the dew point is reached and the vapor becomes liquid. On insulated items that operate below the freezing point of water, this condensed water freezes as it proceeds toward the "cold" surface.
What Harm Does the Water Vapor Do?
1. It radically lowers the insulating property of the insulation. For exampLe:
Thurane has a K. value of .17 Btu per hour per square foot per F per 1" thickness;
Water has a K value of 4.2, or 24.7 times that of Thurane, and
Ice has a K value of L5.6, or 91.8 times that of Thurane.
(K values are for a mean temperature of 70 F, except for ice, the mean temperature is 32 F.)
As the water vapor enters and condenses, it lowers the insulating quality of-the insulation, which tends to accelerate the entrance of additional water vapor due to the lower partial pressure caused by the lower surface temperature of the insulation. Under these conditions, the surface tem perature falls and remains below the dew point, which causes water to condense on the surface.
2. On insulated surfaces above the freezing point, corrosion is accelerated by the condensed water on the metal surface.
3. On insulated surfaces below the freezing point, the water freezes, as previously mentioned. The ice tends to crack the insulation, destroying the value of same.
S I0 U 0 2 9 8 5
THE DOW CHEMICAL COMPANY Texas Division
GENERAL PLANT STANDARDS
WATER VAPOR PRESSURE TABLE (In Inches of Mercury)
(1" Hg = Approximately 1/2 psi)
Temp. - F
-160 -150 -100 - 75
0 + 70 + 90 +100 +120 + 140 + 160
Pressure (Saturated)
0.1009 (10`6) 0.3301 (10'6) 4.666 (10"5> 3.441 (10`4) 3.7645 (10-2) 0.73915 at 80% RH = 0.59132 1.4219 at 80% RH 1.1375 1.9326 3.446 5.881 9.653
56-201
4-25-66 Page 3 of 9
Example:
Find amount of water vapor that will permeate 2" of Thurane (Class L) without a vapor barrier in one year with an average ambient temperature of 70 F and 80% relative humidity.
Vapor pressure at 70 F and807. RH ** 0.59132 (see table)
Vapor pressure at 0 F and 100% RH = 0.03765
Vapor pressure difference =*
0.55367 inches of mercury
Water vapor transmitted peryear through one square foot of surface =
2.5 grains by 8.760 hrs. by 0.55367" Hg _ 6,063 grains/sq.ft ./yr. or 2" 0.866 Ibs/sq.ft./yr .
This is equivalent to a layer of water or ice almost 3/16" thick.
Note:
These calculations were based on a straight line function of water vapor transmission. Actually the transmission rate will vary with the temperature and the relative humidity, and will tend to increase as the insulation deteriorates.
THE DOW CHEMICAL COMPANY Texas Division
GENERAL PLANT STANDARDS
803*100 RV. A
56-201 4-25-66 Page 4 of 9
ST0U02986
Vapor barriers used in the insulation standard specifications, such as cutback asphalt (Foster's 60-25) and Foster's 65X07 Safetee Cl Mastic, have perm ratings of 0.02 for the thickness specified in the standards. With this type vapor barrier used in the above example, the water vapor transmission rate per year would be reduced to only 0.0138 pounds, or less than 3 mils (0.003"). Breathing type weatherproofing materials such as PVA emulsions (Foster's 30-76 or 31-99) and asphalt emulsions are not ' vapor barriers. Their perm ratings range from 1 to 3. In other words, they are from 10 to 150 times more permeable than good vapor barriers. Breathing type materials like these are necessary, however, on hot insulation.
Note: The vapor barrier described for Thurane FR (Dow Polyurethane) is black. Cold insulation is painted white to retard heat gain. For color coating, refer to Specification 57-211.
A white material, Benjamin Foster's Safetee Mpnolar Mastic 60X20 v (Hypalon) is an alternate vapor barrier in Specifications 56-626 and
56-641. This material has a perm rating of .05 for a dry thickness of 22 mils. It has a flash point of 120 F when wet. When dry, it is fire-resistant. See Note 1, Page 5, regarding use of aluminum jackets on insulation.
B. HOT INSULATION
Conventional hot insulation may be applied over bare steel surfaces provided that the temperature of the steel is such that moisture will be driven off, keeping the steel dry.
Where possible, hot insulation should not be used on steel pipe that is normally cold due to infrequent use, such as steam snuffer lines.
Hot insulation in the standard specifications is designed for a maximum exterior surface temperature of approximately 150 F with an ambient tempera ture of 80 F.
Approximate heat loss through hot insulation with an ambient temperature of 70 F and a wind velocity of 0 mph is shown in the table below:
Class and Temperature
C 1,000 F D 800 F D 800 F D 700 F E 700 F E 600 F F 600 F F 4000 F G 400 F G 200 F
Loss, Btu per Sq. Ft./Hr.
150 108 156 130 130 104 134 86 108 38.2
Loss, Btu per Sq. Ft./Yr.
1,314.000
946.000 1,367,000 1.139,000 1,139,000
911.000 1,174,000
753.000 946,000 335.000
THE DOW CHEMICAL CCMPANl Texas Division
GENERAL PLANT STANDARDS
EOJ.ROR REV. A
56-201 4-25-66 Page 5 of 9
18620*101$
For critical process temperatures, more or less insulation may be used than that specified in the standards, except where personnel have ready access, less insulation should not be used unless guards or other protective means are used to prevent possible burns.
In areas where the insulation will likely be frequently removed, Untbestos or Thermobestos should be used.
Note 1 - Aluminum Surfaces
Do not apply conventional hot insulation over bare aluminum surfaces. The alkalis in the insulation will react with the aluminum and deteriorate the same. If surface is too hot for a barrier coat of mastic, insulate with rock wool.
Where aluminum jackets are used over hot insulation, it is essential that a moisture barrier is used (cemented to the aluminum jacket) to protect the jacket from the insulation.
Do not use aluminum jackets on cold or hot insulation in corrosive areas, such as where subject to fumes or spills of acids, alkalis, brines, acid or alkaline salts, or halides, to name but a few corrosives-. The aluminum jackets should not be used in any areas other than those of- low corrosion; that is, where the corrosion rate is *50 mdd or less.
Note 2 - Stainless Steel Surfaces
All 300 series stainless steels are subject to stress corrosion cracking caused by chlorides. (The 400 series stainless steels are immune from this phenomenon.)
All commercially available inorganic insulation contains sufficient leachable chlorides to cause cracking (according to published information on the subject).
Moisture from rain, leaky valves, etc., penetrates the insulation causing a chloride buildup on the hot stainless steel surface.
Failures are most common at 100 C (212 F) and probably will not occur above 170 C (338 F). This then would be in the lower ranges of Class "G" only. The most effective preventive would be to take great care to see that all 300 series stainless steel insulation is kept dry. Chloride leaching cannot take place without moisture. Extra care here could extend the life of an expensive stainless steel line or vessel.
As an additional precaution, in case moisture does get through the insulation, all 300 series stainless steel surfaces (pipes and vessels) in the above critical temperature range that are to be insulated should be cleaned and painted before being insulated as follows.on the next page.
* Milligrams per decimeter square per day.
THE DOW CHEMICAL COMPANY Texas Division
GENERAL PLANT STANDARDS
5030 *EV. A
56-201 4-25-66 Page 6 of 9
STOU02i9`8U
All mill scale should be removed, preferably by light sandblasting as per Specification 57-204, Page 7.
Apply one or more coats of Silicone Coating Dmr-Ma-Lox 70 (Houston distributor: Stockdale, Incorporated, 1525 North Post Oak Road, Houston, Texas, 77024), or owner-approved equal to obtain a minimum total dry film thickness of 2.5 mils.
The first coat should be brushed. Subsequent coats may be brushed or sprayed.
When Foamglas insulation is to be used, coat the interior surfaces of the insulation with one coat of the silicone coating.
Clear Epoxy Coating 57-225, minimum dry film thickness 4 mils, may be used in lieu of the silicone coating provided the operating temperature is not above 300 F.
Eighty-five percent magnesia insulation should not be used on 300 series stainless steel except as the outer layer on double-layer insulation.
C. FIBER GLASS - MINERAL WOOL INSULATION
Specifications 56-627 and 56-647, Classes C-P, D-P, E-P, F-P, and G-P.
Fiber glass and mineral wool insulations are cheaper than standard hot insulation and are designed primarily for personnel protection rather than heat conservation. Where excessive abuse of insulation is likely, fiber glass and mineral wool should not be used. In such cases, use standard hot insulation.
Personnel protection insulation shall normally be installed on all pipe and equipment (except obvious items, such as furnace doors, etc.) whose operating temperatures are above 150 F and where insulation for heat conservation is not required. Such items shall normally be insulated from floor or walkway level up to 7' above the floor or walkway, and for a lateral distance of 3' (on all sides) from the floor or walkway. Protective insulation should be used only where needed. For example, in some areas condensate lines may be stenciled "Caution - Hot" and left uninsulated.
Fiber glass or mineral wool insulation should be used where temporary insulation is desired. These materials should also normally be used for heat traced lines and equipment.
D. ANTISWEAT INSULATION, SPECIFICATION 56-628
This insulation should be used in lieu of standard cold insulation where Class H, J, or Z is indicated in laboratories, mechanical rooms of office buildings, and similar locations. It is cheaper than standard cold insula tion.
This insulation should not be exposed to the weather unless a weather-resistant vapor barrier is used.
THE DOW CHEMICAL COMPANY
Texas Division
GENERAL PLANT >S0T>A0N*DRAERVD. SA
56-201 4-25-66 Page 7 of 9
ST0402989
E. INSULATING MATERIALS FOR ETHYLENE AND PROPYLENE OXIDE AREAS (GLYCOL PLANTS)
Certain inorganic high temperature insulations serve as catalysts to cause spontaneous reaction of these oxides with air.
Only materials that have been checked and approved by the Glycol Laboratory should be used in these areas.
The following materials have been approved:
Hot Insulation - Calsilite 1250 Carey-Temp Limpe t Caltemp Unibestos
Cold Insulation - Thurane FR Foamglas Perlite
F. EXTREMELY COLD (CRYOGENIC) INSULATION
A special study should be made for each installation where operating tem peratures are minus 150 F or colder.
In some instances, double-wall vessels with perlite (expanded silica) between the walls might be more economical than our standard cold insulation. Conventional sealers will not perform at these temperatures. Even rubber becomes brittle as glass.
Perlite has a very good "K" factor. It is incombustible and performs from minus 400 F to plus 1,400 F.
CB&I, as well as others, has had considerable experience in designing vessels for perlite insulation.
G. RELATIVE COST OF INSULATION
All insulation is expensive and should therefore be used only where required for heat conservation, personnel protection, or to prevent freezing.
Insulation should not be walked on. This destroys the insulating quality of the material. Where walkways are not provided for necessary foot traffic, 1/2 pipe sections (transite or steel) should be placed on top of the insula tion and banded to protect same.
Antisweat insulation (Specification 56-628) costs approximately 65% as much as our standard cold insulation.
The applied cost of Thurane and Styrofoam is approximately the same for a given size and class.
Fiber glass - mineral wool insulation (Specifications 56-627 and 56-647) cost approximately 65% as much as our standard hot insulation.
THE DOW CHEMICAL COMPANY Texas Division
GENERAL PLANT STANDARDS
9QS*tOt RCV. A
56-201 4-25-66 Page 8 of 9
ST0402990
Costs will vary depending on the size of the job, the accessibility of the work, etc. As an example, Class F insulation costs approximately $4.40 per linear foot of 12" pipe. A 12" flanged valve, Class F, costs approximately
$22.
Class H insulation (Thurane 1" or Styrofoam 1-1/2") costs approximately $7.85 per linear foot of 12" pipe; $39.25 for a 12" flanged valve.
Monel bands cost almost three times as much as stainless steel bands, but Monel hex mesh is cheaper than stainless steel mesh, due to demand.
H. APPENDIX
To find heat loss or heat gain;
1. Q = *-1 - c3 = heat loss in Btu per square foot per hour x/k + 1/f
t^ = hot side temperature (or cold side in the case of cold insulation)
tj = temperature of exterior surface of insulation
t3 = ambient temperature
x = insulation thickness in inches
k = "k" factor at mean temperature
f = surface resistance, usually approximately 2 in the air
Where ti = 400 F; t3 = 70 F; x = 1"; k = .39 --
We have Q = 400 -70 = 108 Btu per square foot per hour 1/.39 + .5
To find insulation surface temperature:
2. t2 = Q/2 + t3 = 108/2 + 70 = 124 F
3. On cold insulation, when maximum desired heat gain is known, say 7 Btu per hour per square foot at 90 F ambient temperature, Equation 1 reduces to: x = k (Ttj - 90) - 3.] inches. By inserting the k factor and t^ for 7 various temperatures, the thickness x is readily obtained.
Notes
1. Equation 1 is for flat surfaces. For pipes and circular equipment, use equivalent thicknesses xe = r2 loger9/ri. Where r3 and r equal respec tively interior and exterior radius of insulation.
2. Surface temperature and total heat loss will depend on the emissivity (or radiation) of the outer insulation surface.
THE DOW CHEMICAL COMPANY
____Texas Division GENERAL PLANT STANDARDS
501*0f Rev. A
56-201 4-25-66 Page 9 of 9
(c)
16628*101$
Nomograph to find dow point for givon ombiant (dry bulb) tomporoturo for a givon rolativo humidity.
To use nomograph, place a straightedge across the three vertical lines, so that it crosses Line A at the given air temperature and Line C at the known relative humidity; then read the dew point temperature on Line B. Two properties must be known to find the third unknown property on the nomograph.
OFFICE COPY
Biochemical Research laboratory The Dow Chemical Company
/0 70
A SURVEY AND EVALUATION OP PIPE
COVERERS'EXPOSURES TO DUSTS PROM ASBESTOS CONTAINING INSULATION MATERIALS ENCOUNTERED DURING ROUTINE FIFE COVERING OPERATIONS WITHIN THE MIDLAND LOCATION OP THE DOW CHEMICAL COMPANY
Pile: T2.1-1-64
Date: March 21, 1969 By: R. A. DeGesero
Signed Chectced
<24 >/// YuoxaS'L'I. i.
908lnn 1c
PROBLEM Supervision requested that the Environmental Research Laboratory survey and evaluate current levels of pipe coverer's exposures to du3t3 from asbesto3-containing Insulation materials commonly U3ed within the Midland location.
CONCLUSIONS
The present Threshold Limit Value (TLV) for asbestos of
5 mppcf will remain in force until 1971. Barring information
to the contrary, the TLV will then be lowered to 2 mppcf
(million particles per cubic foot).
DAK 01134
Men are encountering time-weighted exposures to dusts frcn insulation materials containing asbestos apprcacning but r.ot exceeding the present TLV of 5 mppcf.
DOW CONFIDENTIAL fexHtBirno.
RESTRICTED: for use within The Cow Chemical Comtuny onlv.
2
3. Men are encountering time-weighted exposures to dusts from insulation materials containing asbestos exceeding the proposed TLV of 2 mppcf.
U. If exposures are to be reduced to within tentatively accepted levels (2 mppcf) either the use of asbestos-containing insulation materials must cease, or pipe coverers must be protected through effective use of approved respirator/ devices and/or local ventilation.
RECOMMENDATIONS 1. Pipe coverers should be educated to the true hazards
associated with the several types of insulating materials they presently u3e.
2. Pipe coverers should be made aware of the several ways of protecting themselves during unavoidable, potential expcsures to dusts containing substances known to be highly toxic, such a3 asbestos.
3. In the future, pipe coverers should be educated to the true hazards associated with any new types of insulation materials to be used, prior to use.
DAK 01135
3
PRESENTATION OF DATA Indoor pipe covering operations were surveyed from 12/24/63 to 1/22/69* Outdoor pipe covering operations were surveyed from 2/20/69 to 3/5/69* Air samples to account for "miscellaneous"
*
portions of the pipe covering functions were obtained from 3/1/69 to 3/5/69*
Sampling and Analysis A total of 141 breathing zone samples were collected
in midget impingers and analyzed employing standard light field microscopy techniques for determining dust concentrations from insulating materials containing asbestos. Concentrations found in samples wre expressed in terms of millions of particles per cubic foot of air (mppcf), according to the following formula.^
mopcf = (mean particles/quarter field) x u x 1000 x sample volume
.-It- (pump flow) x minutes x 3.51 x 1CT2 ------
min.
liter
a 1uuouuo
L?atty, ?. A., INDUSTRIAL HYGIENE AND TOXICOLOGY, Vol. I. Second Revised Edition, p. 198.
DAK 01136
u
The means and ranges of concentrations found during sampling are listed in Table 1.
Job Analysis and Descrlntlon
An environmental Job analysis provides an estimate of
the frequency and duration of men's exposures to dU3t concentrations.
surveyed. The Job analysis expresses as per cent of the day
($ day) the probable time distribution of pipe covering operations,
averaged over several months, on any given day the pipe coverer's
routines can be expected to vary from the estimate.
c.
The Job analy3i3 reconciled input from discussions with pipe coverers and supervision, observations duri.jg sampling,
c
c
-J cz
estimates provided by an industrial engineering time study, and a
C LC
luestionnaire filled out by the pipe coverers. A sample questionnaire
13 found on page i of the Appendix.
The questionnaire requested that men estimate the
per cent of time per day they spent working with the most common
insulating materials. Men's averages were converted into ratios
of time spent
day) per operation and material, and are listed
in Table 1.
Thirty-two per cent (26 men) of the Midland coverers
responded. Responses concerning rarely used materials (e.gcork,
styrofoam, some putty adhesives, etc.) were set aside. Other
information furnished by the coverers included:
DAK 01137
m
1
m
n
*
5
Average age:
Years covering within Dow: Years covering out3ide Dow: Wear respirator?
Which material(s) are the dustiest?
40 years 18 0 Yea: 17 men; Ho: 9 men
JCaylo: Fiberglas: High temp.: Superpower: Mag oxide: Aircell:
16 men 14 men 11 men 5 men 2 men 2 men
Time-Weighting Exposures Men'3 exposures to du3ts from asbestos-containing
insulation materials were estimated by "time-weighting." The exposure frequency and duration (# day) to each material 13 multiplied by the mean concentration in air of each material, giving a set of "time-weighted factors." The "factors" (procuct of # day x mean concentration) are then added up for the eight hour day:
100#
Time-Weighted Exposure = Z5 i -0
# day x concentration
100#
or, 2 = (time-weight factors) i =0
DAK 01138
b IUUbUI 0
I I flQ fm 1 c
6
Table 1 lists the % day, mean concentrations found, time-weighted factors and ranges for eacn material encountered In the listed Operations. The time-weighted exposures to dusts from asbestos containing materials were a.9 -mppcf (indoor operations) and k.2 mppcf (outdoor operations).
DAK 01139
7
Table 1. TIME-WEIGHTED EXPOSURES OP PIPE COVERERS TO DUSTS FROM ASBESTOS CONTAINING MATERIALS
Operations Materials
Day
Concentrations
(mppcf)
Mean
Range
Time-weight Factor: Asbestos
Remove Mix Cut Apply
Air cell K&ylo Mag oxide Piberglas
No. 1 Plus Armentite Superpower
Air cell Kaylo Piberglas Others
Air cell Kaylo Piberglas Others No. 1 Plus Armentite/
Superpower
Clean up removed covers Stocking ; get new covers Move to Job, set up Breaks, lavatory
1.2 1.6 0.2 2.0
1.6 0.1 0.8
5.9 8.8 2.2 0.6
15-8 19.9
4.5 2.6 4.8
2.4
3-0
2.0
5.0
15.0
11.4 11.2
2.8 13-7
13.* 9.6
3*.9
3.0 11.7
1.7 --
5.7 5-7 2.4
--
9.6
2.1
0.3-24.9 3.7-20.5 1.8-4.6 1.2-33-7
2.2-30.5 2.7-13.5 19.6-6.14
0.6-6.2 4.9-23.1 0.8-2.6
--
0.2-15.4 0.4-22.3 1.2-3.8
--
1.1-39-5
O.9-3.9
8.5 2.4-24.5 1.0 0.1-2.3 2.0 1.4-2.9 1.4 0.1-3.9
0.137 0.179 0.006
--
0.219 0.010
---
0.177 1.030
--
0.901 1.123
- ----
0.461
0.050
0.255 0.020
0.100
0.201
Time-weighted exposure to asbestos containing dusts (indoor) in mppcf
/5 I U U b fj I
DAK 01140
8
Table 1. CONTINUED
Operations Materials
Remove
Mix Cut
' Apply
Air cell Kaylo Flberglas Others
No. 1 Plus Armentlte Superpower
Air cell Kaylo Plberg las Others
Air cell Kaylo Flberglas Others No. 1 Plus Armentlte/
Superpower
Clean up removed covers Stocking ; get new covers Move to Job, 3et up Breaks, lavatory
# Day
1.2 1.6 2.0 0.2
1.6 0.1 0.8
5*9 8.8 2.2 0.6
15.8 19-9
4.5 2.6 4.8
2.4
Concentrations
(mppcf)
Mean
Range
5.2 9.0 10.0
5.1-5.2 3.6-14.0 5.5-20.2
9.6 17.0 21.3
2.5 9.4 2.5
5.9-12.5 14.1-21.6 13.1-25.4
0.9-3-4 6.3-7.4 1.4-3.8
1.5 0.3-3-5 9.2 1.9-17.9 3.6 1.6-6.7 1.4 0.3-2.3 5.2 3.5-7.9
Time-weight Factor: Asbestos
0.062 0.144
0.154 0.017
0.148 0.827
0.237 I.831
0.067 0.125
3.0 2.0 5-0 15.0
8.5 2.4-24.6 1.0 0.1-2.3 2.0 1.4-2.9 1.4 0.1-3.9
0.255 0.020 0.100 0.210
Time-weighted exposure to asbestos containing du3ts (outdoor) in mppcf
= 4.2
I UUbU I J
DAK 01141
'i i f)9nms
It 9
Threshold Limit Values (TLV) A TLV describes that time-weighted concentration of a
material to which men can be repeatedly exposed for eight hours
with no adverse effects on health. A TLV indicates a mean
concentration which can be exceeded, provided there are corresponding
I exposures lower than the TLV.
At present the TLV for dust containing asbestos 13
I 5 mppcf U3ing standard light microscopy techniques. Based on best
I current information, the proposed TLV of 2 mppcf would provide better
-protection. A two year trial period preceeds acceptance of
I proposed TLV's. In 1971, 2 mppcf will be the TLV for asbestos, I unless better information during the interim casts doubt upon the
proposed figure.
I Thl3 report evaluated current exposures using the proposed standard of 2 mppcf if the material in question had even
I trace (<5$) asbestos content. Manufacturers were consulted regarding
the composition of the insulating product(s) found in common usage.
I The following table lists these materials and the per cent asbestos I plus the appropriate TLV for that material.
I
%
DAjr 01142
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DAK 01143
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DISCUSSION Men were found to be working almost exclusively with asbestos-containing materials. Their time-weighted exposures to ,dust3 from the asbestos-containing materials were in excess of the proposed TLV of 2.0 mppcf and barely under the present TLV of 5 mppcf. Steps should be taken to lower the time-weighted exposures to within proposed acceptable limits. Several means of reducing the time-weighted exposures are apparenti
1. Cease using asbestos-containing materials. If use of asbestoscontaining materials was stopped, exposures would be reduced to acceptable levels, even though some low-level exposure would be experienced until presently installed coverings have been replaced due to natural attrition.
c
c C
c
c
2. Effective use of approved respiratory devices. Respiratory protection is practical for Jobs which are of short duration and infrequent occurrence. It can be seen from Table 1 that Jobs requiring respiratory protection are neither infrequent nor of 3hort duration. Men encounter greatest exposures during the cutting and applying of Air cell and Kaylo. These two operations are done for 50% of the day -- sometimes 100 of the day. Many other operations listed in Table 1 could require
DAK 01144
*
l
k fl
12
use of respiratory devices. Attempts to lower exposures to 2 mppcf by using respirators seem futile.
3. Use local ventilation. This method would be effective if the ventilation could be kept close to the dust source. Pipe coverers1 work routines make this difficult; e.g., working aloft, or in cramped areas.
In the event new types of covering materials are used, men should be instructed regarding the toxic properties of the materials and the hazards associated with using the material. Protective measures to prevent or lower undesirable but unavoidable exposures to the material 3hould be well understood. Any education effort must precede or be concurrent with first usage of new materials.
During this survey, most men voiced strong objection to flberglas, asserting that flberglas insulation materials were far more hazardous than asbestos insulation materials. This contention is not supported by 25 years available field experience and independent laboratory testing on flberglas.
The Environmental Research Laboratory win survey and evaluate upon request any proposed types of insulating materials and relate their usage to the health hazards associated with these materials.
DAK 01145
L I090G 1S
I%
appendix ENVIRONMENTAL RESEARCH QUESTIONNAIRE
f Please answer the following questions as completely as possible, using
average estimates.
I Name ___________________Man # _____ _ Age
Number of years with Dow
. Number of years covering pipe
1 Do you wear a respirator? Yes____No ___________ What make .....
I If yes, list those operations during which you wear a respirator _______
1 What per cent of the day is this?
___ _
__________________
Have you covered pipe or handled covering materials outside of Dow?
1 Yes _______ No _______ If yes, how long did you cover pipe?
I Answer the following if they apply to you.
How much time per day do you:
I (a) Remove old fiberglas covers?
<bi Remove other types of covers?
c List other types you remove:
(C) Mix "plus one" webbers?
1 (d) Use power saws?
Other adhesives?
List what you cut with a power saw:
(e) Use hand saws? List what you cut with a power saw:
tow much time per day do you: (a) work with "air cell" (b) work with "Kaylo"
(c) work with "Hi-temp" (d) Work with fiberglas
fhich job(8) do you consider most dusty?
low often do you do this job(s)?
STOO60I8
I PLEASE Dtvnr
DAK 01146
13
UNIT INDEX Pipe covering operations were surveyed and evaluated. Men received time-weighted exposures to asbestos near the present Threshold Limit Value of 5 mppcf and in excess of the tentatively proposed Threshold Limit Value of 2 mppcf. Steps should be taken to reduce exposures to the proposed new standard.
t
6 IEI9001S
DISTRIBUTION
L. Warren, Field Service Unit #6, 189 Building
R. Wood, Field Service Unit #11, 49 Building
H. Ahlich, Field Service Unit #2, 759 Building
B. VanderXlipp, Distribution, 572 Building
T. J. Madden, Field Service Unit #10, 222 Building (6) J. Bradley, Plastic Prod. Maintenance, 433A Building
3. 3. Holder, M.D., Medical Department, 607 Building H. L. Gordon, M.D., Corporate Medical Department, 2030 ARC
D. B. Morse, Safety Department, 401 Building
S. M. MacCutcheon, Safety and Loss Prevention, 2030 ARC
R. J. House, Division Accounting Staff, 256 Building
L. Anderson. Plant Engineering, 800 Building
- ' t l\\t2 j "Pi "Hi.
* JO
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DAK 01147
Biochemical Research Laboratory The Dow Chemical Company
-?,PF_3 1/
SURVEY AND EVALUATION OF PIPE COVERERS* EXPOSURES TO DUSTS CONTAINING ASBESTOS OR FIBERGLASS, LUDINGTON PLANT
File: T2. l-S-l(w) Date: 10/23/69 By: R. A. DeGesero
S, igned Checked
7
Date Date
/o/a 4/6 9
/j-
t/
&7
PROBLEM Exposures to dusts containing asbestos or fiberglass encountered by the men in the job classification "Pipe Coverer" were determined for the Ludington P.lant.
CONCLUSIONS 1. Pipe Coverers currently encounter an average eight-hour time-
weighted concentration of 4. 4 mppcf from dust containing asbestos.
2. Pipe Coverers currently encounter a time-weighted eight-hour average exposure of 1. 3 mppcf from dust containing fiberglass.
The present TLV (Threshold Limit Value) for exposure to dusts containing asbestos is 5 mppcf. A proposed change in the TLV for such dusts would lower the eight-hour permissible average
DAK 01148
2
exposure to 2 mppcf. The proposed TLV will go into effect in 1971, barring information to the contrary. The TLV for fiberglass is 15 mppcf. Pipe Coverers encounter time-weighted exposures to dust containing asbestos approaching, but not in excess of, the present TLV of 5 mppcf. Pipe Coverers' exposures are in excess of the proposed standard of 2 mppcf. Pipe Coverers are exposed to dust containing fiberglass at levels within the TLV for fiberglass.
RE COMMENDATIONS If eight-hour time-weighted exposures are to be reduced to within the 2 mppcf proposed standard for dust containing asbestos, then a. the use of asbestos containing materials should be sharply
curtailed or stopped, b. Pipe Coverers should be protected through the effective use of
approved respiratory devices, c. local ventilation should be considered where feasible.
DAK 01149
81900001S
3
2. Pipe Coverers should be informed of the hazards associated with the several types of insulating materials presently used and made aware of the ways to protect themselves when handling asbestos
. containing products.
3. In the event that new materials are substituted for presently used insulating materials which contain asbestos. Pipe Coverers should be informed of the particular hazards associated with thq substitute materials.
fih 9 n n n n is
f
i
PRESENTATION OF DATA Concentrations of dust containing asbestos and fiberglass in the breathing zone of workers were surveyed on 10/10/69 at the Luaington Plant of The Dow Chemical Company. A total of 14 breathing cons impinger samples were collected during: cutting of fiberglass, Kavio and Super XM insulating boards, mixing of asbestos containing cements and clean up operations. Samples were subsequently-analyzed using standard light-field microscopy techniques. Dust concentrations determined thus are expressed in terms of mppcf (millions of particles per cubic foot of air), according to the following formula":
-Patty, F. A. INDUSTRIAL HYGIENE & TOXICOLOGY, Vol. I, Second Revised Edition, page 198.
DAK 01150
S I UUUUbbl)
4
(mean oarticJ.es/auarter field) x 4 x 1000 x samDle vol.
rnppct = -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
m inute (prumpr flow) x minutes x 3. 51 x 10"^ li^ter
Job Analysis and Description An environmental job analysis provides an estimate of the
frequency and duration of men's exposures to dust concentrations. The job analysis expresses, as per cent of day, the probable time distribution of pipe covering operations averaged over several months. On any given day the Pipe Coverer's routine might vary from the long term estimate. Two Ludington Plant Pipe Coverers and their supervision were questioned regarding exposure frequency and duration. Also, information from an industrial time study in Midland was utilized. Sampling is carried out on :he basis of what Pipe Coverers do during the eight-hour day.
From January through April, 1969, a major survey of 81 Midland Pipe Coverers was conducted and data gathered from that report has been extrapolated at appropriate places in this report. Although Pipe Coverers at Ludington have a different time distribution than their counterparts in Midland, many of the materials used in Ludington are similar to, or are the same as, those used in Midland. It is assumed that the same materials, handled in the same wav, will give rise to comparable concentrations of dust.
DAK 01151
5
Time-Weighting Exposures An exposure defines that time-weighted average eight-hour
concentration (in mppcf) of dust containing asbestos or fibergiass encountered during the work day. In order to estimate an exposure, the independent variables of concentration and duration and frequenctr of exposure at any given concentration must be reconciled. Time-weighting provides a convenient method for integrating these two independent variables. Breathing zone concentrations are obtained for each operation of known duration with each different type of material Pipe Coverers commonly handle during the course of their work. The process of time weighting the concentrations and times thus obtained is defined by the following formula:
100% time-weighted average (8-hours) = 2 x (% day x concentration)
i =0 100% or, 2 = (time-weight factors). i =0
Table 1 lists the operation, the per cent of time spent at that operation, the concentration, the range of concentrations and the fraction per cent of day multiplied by the concentration (e_._g. , time-weight factors). The sum of these time-weight factors is the time-weighted exposure to
DAK 01152
6 asbestos or fiberglass containing dusts. For asbestos containing dust the eight-hour average time-weighted exposure is 4. 4 mppcf. For fiberglass containing dust the eight-hour average time-weighted exposure ik 1. 3 mppcf. Appropriate labeled entries indicate which readings from the Midland survey have been extrapolated into this report.
DAK 01153
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EXPOSURES TO ASBESTOS AND FIBERGLASS CONTAINING DUSTS ENCOUNTERED BY
PIPE COVERERS (INDOORS) A T LUDINGTON P L A N T ^
Tim e-w eighted average 8-hour exposure, asbestos dust = 4.40 mppcf T im e -w e ig h te d aves-age 8 -h o u r exposure, fib e rg la s s dust = 1. 32 m ppcf
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Threshold Limit Values (TLV's) The TLV describes that time-weighted concentration of
dust containing asbestos or fiberglass in the breathing zone that men can repeatedly encounter for eight hours per day, five days per week, with
/
no adverse effect on health. The TLV can be exceeded for brief periods provided there are corresponding exposures of equal duration lower than the TLV. The present TLV for dust containing asbestos is 5 mppcf using standard light microscopy techniques. Based on best current information, a proposed TLV of 2 mppcf would provide better protection of men's health. A two year trial period precedes acceptance of the proposed TLV. During this time contrary evidence can be brought forth. In 1971, 2 mppcf will be the TLV for asbestos containing dusts, barring information to the contrary.
Men currently encounter 4. 4 mppcf of dust containing asbestos (time-weighted 8-hour average). This number approaches, but does not exceed, the present TLV of 5 mppcf. Such an exposure level is consistent with those found in a survey in the Midland location. Men were exposed in the Midland location to 4. 2-4. 9 mppcf. The men's current exposures to dust containing asbestos are in excess of the proposed 1971 TLV.
c
dak 01155
Qqqnnnnis
9
Men currently encounter exposure to dust containing fiberglass at 1. 3 mppcf. This exposure is well within the TLV for fiberglass (15 mppcf).
DISCUSSION Pipe Coverers at Ludington encounter concentrations of dust containing asbestos in excess of the proposed TLV of 2 mppcf. If supervision desires to lower exposures to within the proposed standard, several means of exposure abatement might be considered. Replace asbestos containing insulating materials. At present, Ludington Plant Pipe Coverers use Kaylo and Super XM insulations predominantly. Occasionally, Thermobestos, 35% Magnesia, Cary Block insulation and BEH Monoblock insulations are used. All of these contain asbestos. The contribution to asbestos exposure from occasionally used materials is thought to be insignificant when compared to exposures caused by using Kavio and Super XM. Insulation manufacture re rs are beginning to produce materials which can rake the place of Kaylo, Super XM, Thermobestos, and perhaps J M & Cary block insulation materials; Carytemp 1500 is one such material which could be substituted for the asbestos containing materials. Carytemp 1500 is an inert silicate which does not present any known toxicological hazards. Fiber glass can also be used in some areas where asbestos containing materials
DAK 01156
10
I I
L
I
are currently used. Presently, no feasible substitute is available for the cements or muds containing asbestos.
; The effective use of approved respiratory devices. Respiratory protection is practical for jobs which are of short duration and/or infrequent occurrence. Approved respiratory protection means that the devices have Bureau of Mines approval. Two such devices on the market are the Dustfoe #66 and the Sureguard R2090. Respirators must be properly fitted and worn to provide protection.
Men work with asbestos containing materials for 57% of the day and may receive low level exposure the rest of the day from dust on clothes, in storage areas, etc. Attempts to lower exposures to
2 mppcf through the use of respiratory protection is undesirable but may
be necessary until better replacements are available. Use of respiratory protection is recommended under any circumstances which appear dusty to personnel. In the Midland location Pipe Cove re rs use approved respiratory protection during most removing, mixing, cutting and applying operations of asbestos containing insulating materials in lieu of substitutes. Table 2 lists those Ludington Plant operations during which respiratory protection should be used.
DAK 01157
C c c c
c c c
11
Table 2. MINIMAL* RESPIRATORY PROTECTION REQUIREMENTS
Operation Mix muds Cut Super XM Apply Super XM Clean up asbestos containing cuttings
% Dav 5.0 5.2
12. 8 4.0
27.0
Time-Weight Factors Eliminated / 0. 7750
0.4680
0.7296
0. 6760
2.6486 =
Reduction in eight hour time-weighted exposure is:
,-
4. 4 -2. 6
New time-weighted 8 -hour exposure = 1. 8 mppcx
Proposed TLV = 2. 0 mppci
t m rin ric x i
-Pice Coverers should wear approved respiratory protection whenever they encounter obviously dusty conditions while removing, cutting and applying asbestos containing insulations.
PAK 01158
ST0000658
12 Use local ventilation. This method would be effective if the ventilation could be kept close to the dust source. Pipe Coverers* work routines make this difficult; e. g., working aloft or in cramped areas. *" In the event new types of covering materials are used, men should be instructed regarding any hazards associated with using the material. Protective measures to prevent or lower undesirable but unavoidable exposures to the materials should be well understood. Any educational effort must precede or be concurrent with the first usage of new materials. Smoking is particularly discouraged among Pipe Coverers. Recent studies indicate a correlation between cigarette smoking and increased frequency of lung cancer among Pipe Coverers.
DAK 01159
13
UNIT INDEX Pipe covering operations at the Ludington Plant were surveyed and evaluated. Data gathered at Ludington and in Midland indicate that men
t
encounter a time-weighted average exposure to asbestos containing dusts of 4.4 mppcf. This exposure i3 within the present TLV (5 mppcf) for asbestos containing dust, but exceeds the proposed 1971 TLV of 2.mppcf. Current time-weighted exposure; to dust containing fiberglass is 1. 3 mppcf. This exposure is within the TLV for fiberglass (15 mppcf). Recommendations are made to lower asbestos exposures to within the proposed TLV.
DISTRIBUTION R. C. Middleton, Safety Department, Ludington Plant H. L. Gordon, M. D., Corporate Medical Department, 2030 ARC B. B. Holder, M. D., Medical Department, 607 Building D. B. Morse, Safety Department, 401 Building S. M. MacCutcheon, Safety & Loss Prevention, 2030 ARC C- (j^ram e.\r~] Co r jo- Wcjl- 3 3.4)30 -- L - a- ^ W. Snodgrass, Maint. Service Admin., 49 Building (7/9/71)
RAD:sjl
TT
SAFETY AND LOSS PREVENTION MANUAL
FOR CONTRACTORS
| CO
s o eo GO co
' CO : co
THE DOW CHEMICAL COMPANY Engineering & Construction Services
February, 1970
SAFETY AND LOSS PREVENTION MANUAL
FOR CONTRACTORS
"It is the objective of Engineering and Construction Services to establish and maintain an active, successful accident prevention program that will ultimately result in top safety performance by contractors doing work for The Dow Chemical Company."
THE DOW CHEMICAL COMPANY Engineering & Construction Services
February, 1970
ST0 91 8667
r
SAFETY MANUAL FOR CONTRACTORS INDEX
This manual supersedes Safety Manual and Procedures for Contractors dated February, 1966.
Safety Rules
Introduction
1 General Safety Rules 2 Emergency Procedures 3 First Aid--Injuries--Reports 4 Individual Action 5 Vehicles and Traffic 6 Protective Equipment and Clothing 7 Fire Protection 8 Machinery, Tools and Equipment 9 Ladders and Scaffolds 10 Danger, Warning and Caution Tags 11 Safe Work Permits 12 Excavations, Floor Openings,
Barricades 13 Radiation 14 Demolition
Page
1
3 3 4 6 8 9 11 18 22 25 26
27 28
r
i.
STO198668
F==-
INTRODUCTION
This safety manual contains the minimum safety rules and procedures for performance of work by contractors and their subcontractors as required by Engineering and Construction Services, The Dow Chemical Company, for any division, subsidiary or affiliate, hereinafter referred to as "owner." This manual will apply at all Engineering and Construction Services project locations unless the owner has an existing set of safety rules specifically for contractors. Exceptions to this manual, or any part thereof, will be agreed upon prior to starting any field work. The owner will be represented on construction as defined in the contract and hereinafter referred to as "owner's representative."
Contractor assumes and has the full responaibility and liability for the safety of its agents, servants and employees and for the compliance of its subcontractors and anything contained herein does not relieve the contractor of such responsibility or liability.
Safety rules and procedures are an integral part of each contract and must be carried out fully, as any other specification for the job. The contractor will be held responsible for his subcontractors conforming with these safety rules and procedures. Any exception to the rules set forth herein, during the course of any project, must have prior written authorization from the owner's representative.
Contractors and contractor supervision unable or unwilling to secure personnel performance in keeping with these rules will not be acceptable as supervisors. Contractor employees who exhibit a poor attitude toward safe work and safety procedures will not be acceptable. Employees leaving a job due to safety violations will not be allowed to return to any owner's work without proper authorization from the owner. The contractor's safety record will be one criteria used to judge his qualifications for bidding.
T I
STO 198669
In addition to the rules set forth herein, contractors working in or near an existing operating facility must be cognizant of and conform to owner's safety rules for that area and any federal, state or local laws governing.
Should any procedure set forth herein conflict with applicable federal, state or local laws, the latter will apply.
1.0 GENERAL SAFETY RULES
1.1 The contractor shall actively and adequately promote safe working performances on the part of his employees. He shall participate in activities to this end, sueh as safety organizations, incentive award programs, contractor-owner programs, etc. It is expected that each contractor will conduct his own safety programs to best suit his particular needs.
1.1.1 American Standards Azsociation,Z-16.1 Standard, "Recording ml Measuring Work Injury Experience," shall be used as a guide to classify contractor injuries.
1.2 Prior to starting any field work on each job, the owner's representative will conduct a prejob safety conference with an authorized representative of the contractor, a manufacturing representative, when available, available subcontractor's representatives and owner's Safety Department representative, when available. At this time, the nature of any chemical hazards or special safety rules for the area will be reviewed with the manufacturing representative and the contractor will be provided with printed copies of area rules where applicable. The "prejob safety check sheet" form {see sample) will be prepared by
1
F-=^
( 1C I COMtlnCTKM KFUTUHT mum urirr omc m
STO.I 98.670the owner' reprrees*eenntuative and a Copy
furnished to the contractor.
1.3 An effective system of indoctrination and education of employees in safety and loss prevention shall be provided by each contractor. Contractors shall inform all their employees of all safety rules and all safety procedures before working in an owner's plant.
1.3.1 Contractors shall inform all of their employees of the location and the use of nearest safety shower, eye bath and emergency equipment such as gas masks, fire extinguishers, and fire blankets.
1.4 Contractors shall use a regular system of work inspection to detect and correct hazardous conditions, safety rule violations and unsafe working conditions. These safety inspections shall be reported to owner's representative in writing each week.
1.4.1 Orderliness is a basic requirement for all jobs and must be maintained at all times. Special attention must be given to maintaining clear walkways and roadways, removal of trash, removal of slipping and tripping hazards and proper storage of materials. Contractors must make every effort to keep mud, slush or other slippery substances off of plant roads. In cases where this cannot be avoided, contractors must clean the roadways immediately.
1.6 Temporary buildings and material storage areas shall be set up as neatly as possible to present an orderly appearance.
1.6.1 Temporary building shall be sheeted with noncombustible material, such as transite or metal siding and roof, and each must be identified with the contractor's name.
1.6.2 Metal buildings served with electricity mnat hare the ikin of the buildinf property grounded aa well aa the aerrice entrance awitch.
1.6 Contractor* muat furniah traah container* made of metal, each with metal cover* kept in place.'
1.7 Contractors muat report to the owner'* repreaentative, by name, thoae employees discharged for aafety rule infraction*.
1.8 Contractors shall maintain continuous aafety planning to cover jobs where circumstances have changed and new hazards require new controls.
2.0 EMERGENCY PROCEDURES 2.1 Contractors muat inform their employees of existing plant procedures for first aid and ambulance calls. If none exist, the contractor shall submit to the owner's representative prior to starting work, an outline of the procedure to be followed.
2.2 In the event of an explosion or fire, contractor personnel working in the area affected must observe the following rules.
2.2.1 Shutdown all equipment in operation and leave the area at once.
2.2.2 Report to your company field office immediately, in person or by phone.
2.2.3 DO NOT re-enter the area until authorized by the owner'* representative.
2.2.4 The contractor shall notify the owner's representative in person or by
4
ST0I9867I
telephone as toon as possible that all employees in the area are accounted for or that specific employees cannot be accounted for.
2.3 If operating a motor vehicle in an affected area, turn off engine, get out of the vehicle, and be prepared to leave the area if necessary. Motor vehicles, other than emergency units, must not be driven into an area downwind of a gas release. Barricades across plant roads mutt be honored by all vehicles at all times.
2.4 Contractors shall inform their employees of pertinent emergency signals and procedures for the area in which they work. If none exist, the contractor shall outline and inform employees of steps to be taken in the event of disaster emergencies that could arise.
3.0 FIRST AID--INJURIES--REPORTS
3.1 The owner's representative shall be notified immediately in the event of any death, occupational disease, disabling injury or potentially significant injury to a contractor employee (whether or not it is determined that "lost time'' will be involved) while at work on the owner's job.
3.1.1 The contractor must thoroughly investigate, determine and report all details of an accident and cooperate with the owner's inspection teams.
3.1.2 A written report must be submitted on every injury requiring medical treatment of any kind, to the owner's representative on the job, no later than 10:00 a.m. of the day following the injury. Also any near miss, potentially serious or hazardous condition that occurs, must be reported in the same manner, although no injury
5
r
to personnel may be involved. Forma for these reports, "Notice of Contractor Accident and Property Loss," are available through the owner's representative (see sample).
3.1.3 All fires must be reported regardless of duration or extent.
3.2 Employees must report any injury to their immediate supervisor even though it may be considered slight.
3.2.1 The contractor will assure that all injured personnel report to a recognised medical facility.
3.2.2 In the event of any serious injury, an ambulance MUST be called.
3.2.3 In the event of accidents ambulance run, etc., contractors must exert all possible effort to keep onlookers from the scene. The only personnel required in such areas are those directly engaged in assisting in the emergency.
3.3 Employees must not attempt to remove foreign material from the eyes, except by washing with water. If foreign materials get in the eye, the eye must be washed immediately with running water, preferably at an eyewash station and the washing continued uninterrupted for at least fifteen minutes. It is vital that the injured employee and others who are able to help him make sure that thorough and' 'complete washing of the eye is accomplished.
3.4 If chemicals come in contact with the body, the affected parts must be washed with running water for at least fifteen minutes. To
6
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make sure that adequate washing is accomplished, shoes and clothing covering affected parts must be removed. The owner's representative must be consulted before reuse of clothing and shoes that may have been contaminated.
4.0 INDIVIDUAL ACTION
4.1 Horseplay in any form is not allowed.
4.2 Running in the job site must be avoided except in case of an emergency.
4.3 Personnel must not climb through, under, over, or between railroad cars of a train except in the performance of assigned duties.
4.4 Personnel must not make inoperative or operate safety devices such as relief valves, deluge valves, gate valves, electrical and mechanical interlocks, guards, electrical switches, etc.
4.4.1 Any accidental interruption of lines or equipment in service or any irregularities observed must be reported to the owner's representative immediately.
4.5 Unsafe shortcuts, such as walking pipelines, sliding down pipe or stanchions and cutting comers to save a few steps, must be avoided.
4.6 Tools, materials or equipment must not be intentionally dropped or thrown from one level to another unless adequate precautions have been taken to assure that no injury to persons or damage to equipment will occur.
4.7 Personnel must not ride a load being handled by a crane. Slings, hooks, etc., must not be ridden, except where a crane basket or a bosuns' chair and safety belt are used.
8
STOI 98673
4.8 Personnel must not walk, drop or jump onto a transite roof. Care should be exercised while erecting new transite roofs.
5.0 VEHICLES AND TRAFFIC
5.1 Personnel will comply with all safety rules and signs regarding traffic and vehicles at all times.
5.2 The maximum speed limit on open roads in the plant is 25 miles per hour and 10 miles per hour within work areas, unless otherwise designated by signs.
5.3 Vehicles stopped on plant roadways for the purpose of loading or discharging passengers must not be pasted in either direction except, after coming to a complete stop, the vehicle may be passed at no more than 10 miles per hour provided the way is clear.
5.4 Fuel tanks on motorized equipment must not be filled while the engine is running or when welding or other hot work is being done nearby. Smoking will not be allowed during fueling operations.
5.5 Equipment such at welding machines, pumps, etc., shall not be transported with the engine running.
5.6 All equipment must be in safe mechanical working condition at all times. In addition to complying with state requirements as to brakes, lights, signals, horns, mufflers, etc., vehicles must be periodically inspected by a representative of the contractor. Necessary repairs and adjustments must be made prior to their use on owner's property.
5.7 The use of winch trucks, flatbeds, stakebeds, etc., as transportation for personnel
9
p
will not be permitted unless adequate safety provisions are mads and the vehicle is adapted for that purpose. In any case, the number of personnel must not cause overcrowding.
6.8 Riding of "Cherry Pickers" or cranes is permitted only when adequate safety provisions such as seats, platforms, rails, etc., are provided for passengers.
6.9 The maximum number of people who may ride in a pickup truck is three in the cab and six seated on the floor of the bed, or on approved "built-in" seats.
5.10 Personnel must be sitting down at all times when the vehicle they are riding is in motion and must not have any part of their body over the sides.
5.11 Pedestrian paths and walkways must be used whenever provided. In their absence, personnel using streets and roadways must walk facing approaching traffic, on left-hand side of road.
5.12 The following rules must be observed in the operation of cranes, cherry pickers, winch trucks and other equipment having booms or extended loads which extend 15 feet or more in front of or to the rear of the equipment.
5.12.1 Stop at all stop signs.
5.12.2 At intersections, when the equipment is to proceed straight across a thorughfare or turn either way, the equipment must stop; the flagman must get off the equipment, clear all traffic, then flag the equipment through the intersection or around the corner.
5.12.3 Before entering any thoroughfare, street, road, etc., from a
10
STO198674
work area, the flagman must clear the traffic and flag the equipment onto the road.
5.12.4 All booms or loads extending more than 15 feet must be marked or flagged with high visibility material when moving on plant roads.
5.12.5 A flagman must be provided and swinging must be controlled with a tag line when moving in a congested area or where there is personnel.
5.12.6 Hauled material that overhangs the sides or ends of a truck must be red flagged at the extent of the overhang. Loads must not be hauled from a single suspension cable that allows free swinging beyond the sides of the vehicle. Loads or vehicles that extend out of the normal road lanes require flagman or escorts.
5.12.7 Contractors must check vertical clearances on the route to be used prior to moving equipment or high loads.
5.13 Contractors must determine from the owner's representative when and which roads are to be used, prior to moving extremely heavy loads such as large rubber-mounted equipment and low-boy loads.
6.0 PROTECTIVE EQUIPMENT AND CLOTHING
6.1 The contractor and his employees shall recognize the importance and the use of special protective equipment and clothing.
6.1.1 The contractor shall be responsible for knowing and enforcing special owner area or job rules requiring special personnel protection.
11
6.1.2 Contractor! shall provide their employee* with the proper protective equipment required.
6.2 Approved safety glasses shall be a minimum requirement on all job* at all time*. Safety glasses with side shields are required when grinding, chipping or performing any job where side shields would afford protection from flying particles.
6.2.1 Approved safety glasses must fulfill federal requirements (GGG-G-513) for drop ball testing and safety code for polarized "Strain" pattern.
6.2.2 Employees wearing contact lens must wear chemical goggles.
6.3 Chemical goggles, approved prior to their use, are required for working in or entering certain chemical areas which are potted with signs, or while doing chipping or power tool cleaning work on pressurized lines or equipment which contains hazardous chemicals.
6.3.1 All employees working in the vicinity of hazardous chemicals must know where the nearest safety shower and eye bath facilities are located.
6.3.2 When chemical type goggles are in use, the headband must be around the back of the head, not around the safety hat.
6.4' Approved safety hats are required for all contractor work. Metal hats must not be used where electrical hazards exist.
6.4.1 Approved safety hats must fulfill requirements in Federal Specification GGG-ll-142b. The major requirement in
12
STO198675
this specification says, "The specimen must withstand the drop of an 8-pound spherical weight, approximately 3.8 inches in diameter, from a distance of 6 feet, without breaking the hat, bottoming out or breaking suspension." Most skull caps, scalp guards, bump helmets, etc., will not meet this test. Safety hats shall not be drilled or punched for ventilation holes, or edges trimmed off hats.
6.6 All personnel shall wear air hoods, or equivalent, supplied with Altered air, when sandblasting or applying volatile or toxic material inside tanks, rooms or any other area not adequately ventilated.
6.6 Safety belts or harnesses, with lifelines attached, are to be worn by employees when performing work in elevated positions where the use of scaffolds or ladders is impractical and where a slip might result in a serious fall. -
6.7 Personnel must wear owner approved life jackets or otherwise be protected by handrails or lifelines when working over water wherein a drowning hazard exists.
6.8 Personnel shall wear personal clothing that is safe and proper for their job. Wearing of canvas shoes, sneakers or houseshoes and working in an undershirt, shorts or stripped to the waist is prohibited. Safety shoes are strongly recommended.
6.9 Fixed blade knives used as tools of the trade must be carried in sheaths while not in use.
13
i--
7.0 FIRE PROTECTION 7.1 Accumulation at traih, oily rage, combuatible material! and limilar fire hazard! of any nature will not be permitted. 7.2 The area around welding operation! muit be kept free of hoaee and flammable material of all kind. 7.2.1 There muat be a fire extinguiiher or water hoae eaiily acceiaibie for each welding, cutting, burning or other auch operation!, located in cloae proximity to the operation. It ii the contractor'! responsibility to obtain the required fire extinguiihera for hia welding operations. 7.2.2 Special care muit be taken during overhead welding operation! to safeguard personnel and prevent falling aparka from starting a fire. 7.3 All, tarpaulins shall be fire-retardant and identified as such by stenciling: "FR-treated (date)" with a minimum of 2" letters in diagonal corners. In lieu of this treatment, fire-proof blankets such as fiberglass or asbestos are acceptable. 7.3.1 Contractors must inspect and test all tarpaulins at least once each six months to be sure that they are still fire-retardant. Tarpaulins needing it must be retreated or removed from the plant immediately. At this time the tarpaulins must be restenciled in the same manner as in 7.3 above. 7.4 Fire plugs, extinguishers, hose racks and other emergency equipment, shall not be coyered or blocked ana fire equipment lanes must always be kept clear. 7.5 All heating units for offices, shops, work areas, change rooms, etc., must be in good working order and periodically inspected. Gas units must be provided with "flame-out" protective devices and electrical units must be 14
STOI 98676
grounded. All heating units must be turned off at the end of each work day.
7.6 Flammable or explosive type material such as fuel, oil, cleaning agents, etc., must be properly contained, clearly identified, separately stored and kept clear of work areas. Appropriate signs must be provided in storage areas.
7.7 All cans used for transporting or transferring gasoline or fuel must be labeled by Underwriters' Laboratories or Factory Mutual Laboratories.
7.8 Fuel storage tanks, filler hoses and the dispersing vehicle or containers must be properly grounded.
7.8.1 A quick shut-off valve is required on the dispensing end of fuel hoses.
7.8.2 Equipment fuel tanka must not be filled while the engine is running.
7.8.3 Smoking, welding or any spark- or flame-producing operation must be stopped in the immediate area during refueling operations.
7.9 Welding rod cabinets presenting a fire or safety hazard will not be permitted. Cabinets of fireproof materials equipped with strip heaters are recommended. If light bulbs are used, they must be securely guarded with adequate spacing in regard to the cabinet and to stored material. Metal cabinets must be grounded in an approved manner.
7.10 Volatile materials must not be applied near an open flame. If such material is to be applied in a vessel, or other poorly ventilated, confined area, only explosion-proof lights ana connections will be used. The contractor must designate such areas as "No Smoking."
7.11 Heating equipment for freeze protection of concrete must be approved by the owner's representative prior to use.
15
r
7.12 Welding or cutting torchee end hoses must not be connected to cylinder* when itored in any encloeure or building. When work it abut down and equipment i* unattended, cloie all valves at the gas and oxygen cylinders, bleed lines and check five minutes later for
resaure build-up. If there is no build-up. bleed oses at the torch, remove hoses from cylinders and store. No smoking will be permitted during this shutdown procedure.
7.13 Gas and oxygen cylinders must be handled with care, properly supported in an upright position away from any source of heat or flame and securely tied off. All cylinders not in use must have their caps in place and stored as above.
7.13.1 Oxygen cylinders in storage and not in use must be separated from gas cylinders by a fire retardant partition or a minimum distance of 10 feet. 7.13.2 When gas and oxygen cylinder* are lifted by hoisting equipment, a basket, a cradle, or similar handling device must be used. Cylinders must not be lifted by the valve protection caps.
7.14 AU "No Smoking" restrictions must be strictly observed. Smoking is not permitted in vehicles in designated "No Smoking" areas.
7.15 Compressed gases must not be used for cleaning of clothes, the body or work areas. Oxygen must not be used for pressure testing purposes.
7.16 ^ Adequate ventilation must be provided when cleaning agents are used.
7.17 Contractors must not dump flammable or toxic materials into sanitary sawen or waste water system without prior clearance of the owner's representative.
16
STOI 98677
8.0 MACHINERY, TOOLS AND EQUIPMENT 8.1 The safe designed capacity, of any tool or piece of equipment must not be exceeded. Tools and equipment must not be modified in any manner that reduces the original safety capacity.
8.2 All contractor owned, leased or rented equipment must be in safe mechanical working condition to render safe service at all times.
8.2.1 Equipment must be inspected by contractor supervision prior to its use on a job and periodically thereafter to insure that it is in safe working order. Crane inspection must be submitted in writing to owner's representative using the owner's "Hoisting Equipment Inspection" form. (See Sample.) Special attention must be given to such items is cables, guards, booms, blocks, books, grounds, electrical cords ana safety devices. Equipment must be shut down before repairs or adjustments are made.
8.2.2 Defective tools and equipment must be removed from the job immediately and if repairable, must be properly repaired before reuse on owner's job.
8.2.3 Machinery, tools and equipment must not be operated without ail guard* and safety devices in place and functioning properly.
8.2.4 The contractor has the complete responsibility for a safe operation when using hoisting equipment to make lifts. The contractor shall verify weights of loads to be lifted. No load shall be lifted which exceeds the manufacturer's rated capacity of the crane. When one of the
17
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18
sjoisini
following
prevail, the
contractor must submit in writing, using
the owner's "Critical Lift Check Sheet '
(see- sample), an outline of the safety
planning for the lift to the owner's
representstire prior to starting the lift.
a. The load exceeds 80% of rated load charts for crane.
b. The load exceeds 60% of rated load chart for crane, and possible failure would endanger existing facilities.
c. Two booms are required to make the lift.
d. Poles or derricks have been erected for this specific lift.
8.2.5 If burning of lugs or other such flame producing operations may be required during crane hoisting operations, arrangements for proper safe work permits must be made before the lifting operations begins.
8.3 Equipment with exposed gears, belts, couplings, etc., must be provided with proper guards.
8.4 Electrical tools and equipment operating at more than 32 volts must be properly grounded. Certain test equipment such ss oscilloscopes, vacuum tube voltmeters and signal generators, as well as certain areas where exposed d-c equipment is used, do not require grounding ana proper operational procedures must be ascertained from the owner's representative.
8.6 Only 32-volt, or less electrical service is to be used in connection with drop lights when working inside metallic vessels, unless 115-volt service is essential for the operation of equipment.
19
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STOI 98679
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22 23
8.6 When arc welding is being done in an area restricted by a safe work permit, the grounding lead must be connected to the work within the limits as provided in the safe work permit. 8.7 Any contract provision for connections to an owner's plant services for construction use must be cleared with the owner's representative. Authorized connections must be made under the direction of the owner's personnel. The turning off and on of the supply shall be done only by authorized owner's personnel. 8.8 Gloves must not be worn while using grinders, drills, saws or any tools where gloves are apt to become entangled. 8.9 Loose clothing must not be worn while working around machinery. 8.10 Personnel must not crank any machinery with their feet. 8.11 Hose connectors and adaptors must be of a standard manufacture and used only for the type of service intended.
8.11.1 In order to insure positive locking at all times, connectors must be in good condition and not abused. Sandblast hose connections shall be the safety lock type which prevents accidental disengagements. 8.11.2 Air pressure on pneumatic tools must be bled down before tools are disconnected from air supply.
24
ST0I9868I
9.0 LADDERS AND SCAFFOLDS
9.1 All ladders must be of the proper length and in good condition before using them. All unacceptable ladders must be immediately removed from owner's property.
9.1.1 Ladders are not to be painted with anything other than clear paint or linseed oil.
9.1.2 All straight ladders must be tied off or held. Stepladders higher than ten feet must be tied off at the top or held at the bottom by another workman. Personnel must not stand on the top step of any stepladder.
9.1.3 When climbing a ladder, personnel must face the ladder and keep both hands free for climbing.
9.1.4 Set straight ladders so that the bottom is out from the vertical about one-fourth of the distance from the upper support to the bottom.
9.1.5 All ladders should be provided with nonskid adjustable feet or properly supported on a level surface.
9.1.6 The area around the bottom of all
ladders must be free from slippery
SUb*^en>4trippmg frussrda--.
_
9.1.7 Ladders are not to be used as pencil or sotffold boards.
9.1.8'THe- top section of extension I ladders are not to be used by themselves.
9.2 The use of,No, 9 soft annealed wire should be minimised on scaffolds.
9,2.1 When, 9
annealed wire is
used, a minimum of tbro separate strands
must be used to tie scaffold handrails,
_____ 9S
n
bracae, etc. The tie* nuit be crossed to form e lock and prevent alippinf in any direction. 9.2.2 Do not reuae No. 9 wire for any
9.3 Makeshift scaffolds such as boxes, crates and drums must not be used.
jsucaatftfoollddsu"aiandaluamluimnuinmum laoddeenrcsi.LJ
TTVTVepi In ipWlaicase* pecified in operating area rules and job specifications or by pnor written approval from the owner's representative.
y 9.6 The following rules apply to all patented metal scaffolds:
9.5.1 Scaffolds must be erected with proper fixtures made for each type of r scaffolding. Scaffolds and associated equipment must not be modified in any manner that reduces the manufacturer's designed performance.
9.5.2 All scaffolds and allied equipment o' must be kept in good repair.
9.6.3 Equipment that is damaged or deteriorated to the extent that it is r unsafe shall not be used. Such equipment shall be removed from the owner's property.
9.5.4 Compensate for uneveness of y ground by using adjusting screen in
addition to proper blocking.
9.6.6 Do not force braces to fit. Adjust v evenness of scaffold until the proper fit
can be made with ease.
y
9.5.6 Use ladders when climbing scaffold rather than the cross braces and
handrails.
26
T
M.,.ULI20tt2am when ^ttmlilwg scaffold rather than the cross
9.6.8 Horisontal diagonal bracing shall v be used at bottom and intermediate
levels of thirty feet to prevent racking of all scaffolds.
9.6.9 Planking ovsrteng shall be 3-6/8" on staakun. scaffolds. 1" by 4" wood cleats shall be nailed mob top of .v planking at each end outside and frames. 5*rby 2" cleats shall be bolted underside each end of plank with 2-1/4" stove bolts.
9.6.10 The maximum spaa for guying or tying off all fixed towns is every 18' of elevation.
y 9.6 The following rules apply to rolling tower * scaffolds:
9.6.1 The minimum base dimensions for towers shall be 5' x 7\ 9.6.2 Towns of a height greater than three tiptpatbe minimum baas dimension mttit be guyed or tied off while being erected, ueed or dismantled. 9.6.3. f>ater bcakae nuiat be applied when not in motion. 9.6.4 Towers must ba. free of man, . material and equipment while being moved. Care must be exercised while moving. 9.6:6 Suxfeee area when tower is being yS moved sialT be free of rabble or any material that may caiwe tbatower to tip. . 9.6.6 Do not attempt to move a rolling tower without euffleent help.
27
. 9.6.7 Do riot extend adjusting screws < beyond the ((mite specified by the
equipment manufacturer. 9.6.8 The minimum aiza for casters shall be 6". Scaffolds higher than 25' must be S stabilized either with outriggers or hand lines while being moved. 9.6.9 Horizontal diagonal bracing is to . be used at the bottom and at ' intermediate levels of 30 feet. 9.6.10 Do not use knee braces or * cantilevered brackets on rolling towers.
~ 9.7 The following rules apply to suspended scaffolds:
9.7.1 Chains or. 1/4" (minimum) steel cable shall be used to support suspended j scaffolds. All suspended scaffolds shall be anchored to prevent swinging. Chains so used shall be made of not lem than 1/4" links* and shall be inspected immediately prior to each use.
*1/4" proof coil loading chain
Safe Load
900 lbs.
. 6/18" proof coil loading chain
* SeleLoed
1,360 lbs.
. 5/16" proof coil loading chain
S Proof-tested Safe Load
2,720 lbs.
> S/16" proof coil loading chain
unlimited Safe Load
6,440 lbs.
9.7.2 The suspended support must be insulated when arc welding is to be performed from platform, thus avoiding "ciri--laLaaeyMjmLsuhacfluent failure.
9.7.3 Block and (alls shall be _ minimum of tiro sheaves for 3/4' rope and the minimum size rope shall be 5/8". Acid resistant rope shall be used in.
=$T0I98683 add or ciwdc ansa Tall ropes shall; placed in an apse container for protection while need in an add area or above operating meehrirvy, pumps, ate. All ropes and blocks mast be inspected sad tasted prior to each use and taken dawn and stored inside at the end of t workday. 9.8 The following rules apply to all scaffolds:
9.8.1 Scaffolds end related material , shall be carefully inspected at regular
intervals and particularly just before using. 9.8.2 Provide sufficient sills or underpinning on all scaffolds to be , erected on filled or otherwise soft ground. Scaffold boards shall not be used for this purpose. 9.8.3 All scaffolds must be plumb and ^ reasonably level at all times. 9.8.4 Anchor running scaffolds to wall . approximately every 28' of length and 18* of height. Use additional care when using pulley arms. 9.8.S Handrailing and access ladders must be used on all scaffolds regardless of height. Scaffolds higher than 30' around columns, tanks, etc., must have access ladders constructed on the inside,
{J.8.6 Scaffolds must not be used as ^ material hoist towers or for mounting
derricks without first determining the losds and stresses involved. 9.8.7 Erect scaffolds in such s manner that ladder is accessible and lined up from top to bottom.
29
9.8.8 Lumber used in the construction
of platforms shall be of good quality and
reasonably straight grained, ft shall be
free from defects such as injurious ring
V
shakes, checks, splits, cross grains, unsound knots, knots in groups, decay
and growth characteristics or any other
defect which materially decreases the
strength of the lumber. Planking shall
not be painted all over, as this would
conceal any defects. Scaffold boards
shall be identified by painting each end.
All scaffold boards *u-"
----- 1
9.8.9 The normal size of planking shall
be determined from Table I. These
values are for planks with the wide face
up, with the loads concentrated at the
center. Loads given in the table are net. Allowance has been made for the weight
of the planking. If select structural coast
region Douglas fir, merchantable
structural square and sound southern
pine are used, the loads may be increased
45 percent.
9.8.10 Planks used for platforms shall be of uniform thickness, laid close together. These planks must be overlapped at the bearers. An overlap of at least 2' must be allowed with the S bearing in the center of the overlap. When planks overhang a bearer more than one-tenth of the length of the span, the planks must be securely fastened to the bearer at the opposite end to prevent tipping.
9.8.11 All nails used in scaffold . construction shall be driven full length.
If double headed nails are used, they shall be driven to the first head only and / may not be used on platforms or walkways. No nail smaller than 8d shall be used in this construction. The design must be such that no nail is subject to a direct pull.
30
3.8.i5ifliaa.6a|t used in
scaffolding, the schedule of loads shown in Table U shall be followed. Loading on cantilever type beams for tool and material hoists is shown in Table IIL It should be noted that the loading at the center of bearing point is 4 times as great as the load being lifted and the bearing should be checked to ascertain if it will support the contemplated load. The inboard end of the beam has a force upward of twice the load and must be securely fastened with no nails in direct pull.
9.8.13 Platforms shall be kept clear of slippery substances and tripping hazards.
10.0 DANGER, WARNING 8i CAUTION TAGS
10.1 Danger Tags (Red)
10.1.1 To insure that operating status of equipment is not changed while it is being used or worked on, red danger tags must be attached to the controls so that personnel will know not to use them. These tags must be used to protect personnel exposed to hazards of equipment and must be respected by all personnel. The personnel responsible for the operation of equipment or their designee must clear and tag the equipment. Any personnel whose safety could be endangered while working on this equipment must affix their tag. Violation of red danger tag rules will result in disciplinary action up to and including rejection from any work on owner's property.
10.1.2 No control such as a valve, switch, clutch, etc., is to be operated by anyone while a red danger tag is attached. If a control must be operated intermittently such as for testing equipment, the red danger tag must be properly removed before each operation.
31
TAMA UH CtNlIM lOAOt *0* 0CA99OU>
flAft* M MUMM
Size Of MANIC
7*70
7il7
3 a tO
Sail
OmnM
DM
0 !<
DM
tmH w IMti*lli t-O/rlstU 7-Vt*r> JMTi*lU
to mm xm ocr ur too M
in mto m too 400 404
IT 333 40*
10 NO 303If HO 123 too mo MO
&M
7s4 *7a.*0
3*0 3 10
3113
3*0
3*10 if IZ
$
440 mNO
1409 3100
2ND
3100
3NO 4*J0
Tamo tt lAt CltrTIR VOAM ON TtMMN OM0 AO
OCAJUO m OOiMOO
UMGTH Of MAN IN 9T
4
300 IIS HO MOO 1130 3030 <330 3700 3040
310 <30 *30 0 1300 1900 1390 3130 7*30
to
330 300 mo <040 M30 9*0 IM 7300
t?
300 NO ug MO >7V3 tf OOO 1MO
14
711
MO MO MO tOOO MO 1070 t*7
10
190 330 900 990 MO 900 ti40
70 74
730 190 400 370 30 110 410 790 30 490
toot MO
TAOU M OAft LOADNtt 90* OHMIC MATtfttAt H040T ON CANTlUViO MAN IN OOIINOO
icnqtm or cantiuvcr tu in rccr
Un 2 7
/I
730 tOO too ao 0
<90 U TOO too no in loo
010 111If
<90 3tO
TOO
730
too
100
1370
7ft
470 350 300
1300
Mft
M
IN
300
410 400
Ml 99 Mf 49 ft 99MW
32
ST 0198685
Attachment of danger tags to equipment controls does not mean that equipment has been cleared to work on. When work is to be done on Ugged-out equipment, personnel responsible for the operation of the equipment are responsible for clearing the equipment and making it safe for others to work on.
10.1.3 Whenever the operation or use of any equipment may endanger anyone, a request must be made to supervision of the group which operates the equipment to clear and tag the equipment. "Clearing" means making the equipment inoperable and safe for others to work on. The authority to clear and tag equipment may be delegated by this supervision to any qualified personnel after supervision has assured themselves that the person delegated can properly clear the particular job involved.
10.1.4 After the group which operates the equipment has cleared and tagged the equipment, each worker or noup of workers who may be exposed to the hazards must tag the equipment for their protection. When red danger tags are attached to equipment by persona other than those responsible for its operation, prior approval from the person responsible shall be obtained.
10.1.5 As the individual jobs have been completed, each worker or group of workers must remove their tags immediately.
10.1.6 The group responsible for the equipment must place their tag first and remove their tags ust.
10.1.7 Red danger tags may be removed only upon authorization of the person designated on the tag. The supervisor of any person who fails to remove a red danger tag when a job has been
33
*
completed may authorize the removal of
the tag after he haa determined to hia
complete aatiifaction that the equipment
can be operated in a safe manner. In the
apace on the tag entitled "Removal Will
Be Ordered By
it ia permiaaible
to designate a daaaification auch aa shift
foreman, electrician, or machinist
instead of a specific individual's name.
10.1.8 At the discretion of the supervisor, locks may be used on valves and switchea in addition to, but not replacing red danger tags.
10.1.9 Tags removed must be filled out and turned in to the owner's representative.
10.2 Warning Tags (Green)
10.2.1 When it is necessary to convey instructions or information prior to operation of equipment controls, green "warning'' tags are to be attached to the controls.
10.2.2 Green "warning" tags should be removed when conditions set forth on the tag have been met.
10.3 Caution Tags (White)
10.3.1 White caution tags are affixed to mechanical or electric equipment by the owner's representative to prevent operation of such equipment by anyone until items on the tag have been completed.
10.3.2 The tag provides spaces for meggering, rotation, final alignment and' lubrication of equipment. When appropriate action has been taken, the personnel performing the work signs and dates the tag.
10.3.3 When tagged equipment is released to the owner, a representative of
34
S.TO I 986.86operations and the owner's
representative sign the tag which is kept by the owner's representative until job completion.
il l) .CAPE WORK PERMITS
11.1 Safe work permits issued by the owner to contractor personnel may be required for certain hazardous locations and conditions. These permits are designed to provide a means of checking at the job site the safety of such jobs as, but not limited to, entering closed vessels: working on electrical gear: welding, cutting on, breaking into or repairing pipelines or vessels in operation or under pressure or that have contained hazardous materials. These permits also cover work involving the use of flame or spark producing equipment in hazardous areas or near an open ditch and work on machinery. 11.2 Contractor supervision must be in close contact with the progress of work as well as communicating with the owner's representative for up-to-date status of operations. Further, contractor supervision must be certain that all personnel involved are informed as to specific procedures and changes in the situation.
11.3 Safe work permits are to be initially requested through the owner's representative ana issued by the owner's operating area or facility supervision involved on any iob where the safe work permit is applicable. More than one safe work permit may be required on certain jobs which will be ascertained upon obtaining each safe work permit. Permits are issued on a day-to-day basis. 11.4 Personnel must give a careful and complete description of tne work to be done to the person issuing the safe work permit.
11.4.1 Where a job presents a serious man hazard due to chemical, mechanical, electrical, temperature or height exposure, it is mandatory that a written safe job procedure accompany the
35
request for the safe work permit. This procedure is to be signed by the owner's representative, process representative, and the contractor, who thereby agree that the procedure aiiows the job to be done safety. 11.5 Directions and restrictions noted on safe work permits must be carefully followed. 11.6 A safe work permit must be reissued for a job if there is evidence that conditions have changed subsequent to the issuance of the original safe work permit. 11.7 Permits issued for jobs that last longer than one day will normally be issued for that job each day. By mutual consent of the parties involved, permits for these jobs may be issued for longer or shorter periods of time. 11.8 Vessels in an existing facility to be entered must be made safe for personnel by such measures as disconnecting, blinding, or double block and bleed on connecting piping. If such precautions are impractical, a detailed procedure for performing the work in a safe manner must be prescribed as specified in Paragraph 11.4.1. 11.9 Vessels in an existing facility to be welded on, or cut, must be positively checked inside for flammable or explosive gas and/or liquids and and safe work permits issued before heat is applied. 11.10 The contractor may request safe work permits for his own protection. Safety checks by the owner for dangerous gases or chemicals should be requested through. the owner's representative when there is any uncertainty. 11.11 All safe work permits in the area affected are automatically cancelled when an emergency signal is sounded and must be reissued after the all clear signal.
36
STOI 98687
12.0 EXCAVATIONS, FLOOR OPENINGS, BARRICADES 12.1 Where a safety hazard would be created for any personnel, excavations such as ditches, trenches, or bell holes should be sloped sufficiently to prevent cave-ins or slides. If sloping is impractical, shoring must be used in cases whenever the vertical dimension exceeds four feet.
12.1.1 Personnel removing shoring after completion of work must not be in the bottom of the excavation. Shoring must be removed in such a manner to prevent cave-in on personnel.
12.2 Contractors must provide adequate barricades, covers, handrails, signals, flagmen, or other appropriate warning devices to protect personnel near any hazardous operation or excavation. Floor openings, open trenches, excavations, etc., shall be covered when handrails or barricades do not provide adequate protection to personnel.
12.2.1 Contractors must notify the owner's representative of necessary obstruction on road shoulders on the day it occurs.
12.2.2 Contractors must obtain approval from the owner's representative at least one day prior to cutting roads or otherwise obstructing traffic on plant roads.
12.3 Grade lines, ropes, chains, etc., must be sufficiently marked in order to be visible day or night
12.4 No obstruction of any kind, whether ermanent or temporary, is permitted within 9" horizontally from the center line of any railroad track ana within 22*-6" vertically from the top of the rail Specific authorization from the owner's representative as well as blue flags are required prior to boring under or excavating adjacent to railroad tracks. Blue
37
flag* must be placed on railroad tracks when the entrance of a train would present a hazard to personnel or equipment. 12.5 In locations where strictly temporary loading or unloading operations are to be undertaken, portable derails must be used by personnel engaged in these operations to present overrunning of the cars by a train. 12.6 Blue flags meeting ICC specifications, available through the owner's representative, must be placed on railroad tracks when the entrance of a train would present a hazard to
Knnel or equipment ana in addition to, or njunction with, derails during loading or unloading operations. Blue lights, available from the owner's representative, must be attached to blue flags at night
12.6.1 Blue flags must be placed on the tracks so they will be in unobstructed view of the train crew and they must be placed a minimum of two-car lengths (100 feet) in front of the end car they are intended to protect. Exceptions to the minimum distance may be made by the owner's representative where existing installations do not allow sufficient space. 12.6.2 Blue flags must be removed immediately when the hazard for which they were inatailed no longer exists. 13.0 RADIATION 13.1 All state and/or federal laws governing use, storage or handling of a radiation source must be complied with. 13.2 A minimum of two qualified people are required for the performance of any radiographic work. 13.3 In locations where a radiation source is used or stored, regulations require that it be marked with a "Radiation Material" sign. This sign is for the purpose of Informing anyone in
38
the areaSiX Qd 2a2r6l2 Resent, and not that a safety hazard due to radiation exists.
13.3.1 Only authorized personnel may enter an area marked by "Radiation Area'' sign. 13.3.2 All areas where a radiation hazard exists must be roped off and marked conspicuously by standard signs at a safe distance from the source of radiation. These signs bear the radiation symbol of magenta (or purple) on a yellow background with the words "Caution--Radiation Area." 13.3.3 "Radiation Area" signs must be removed when a radiation hazard no longer exists in the affected area. 13.4 Equipment containing a source of radiation must not be handled, uncrated or installed without prior clearance with the owner's representative.
14.0 DEMOLITION 14.1 This section specifically covers the demolition (removal of facilities that have been abandoned. Due to the inherent hazards in this type of work, special care must be devoted to safe procedures, scope understanding and communications concerning the safe clearance of work. 14.2 It is not appropriate to make assumptions in any stage of a demolition job. Responsibilities must be delegated only to those whose profession qualifies them to make the necessary judgments and decisions that are required to assure the safest possible prosecution of the job. From start to finish, each person connected with a demolition job must adopt an attitude of "prepare for any possibility." 14.3 The contractor shall make certain that all lines,-services and equipment have been cleaned
39
STO198689
or purged and properly cleared for safe removal. Ail lines (including water and steam) are to be considered hot until positive safe clearance has been obtained. 14.4 Special care shall be exercised to locate and mark old underground or otherwise hidden lines, cables and sewers usiruf the best available information and owner's assistance. 14.6 The prejob safety meeting with the contractor, as covered in Section 1 of this manual, shall devote special attention to preplanning the safety aspects of demolition jobs.
14.5.1 Steps of dismantling and loads to be handled shall be reviewed with the owner's representative prior to starting work. 14.5.2 Temporary provisions must be made where safety showers, eyewash baths and fire extinguishers are being moved in the work area.
40
STOO 11>I 85
SAFETY AND LOSS PREVENTION MANUAL
FOR CONTRACTORS
AMBULANCE FIRE ACCIDENTS
EMERGENCIES
>
DIAL
666
THE DOW CHEMICAL COMPANY TEXAS DIVISION
Aoril. 1970
STOO14186
ffl
SAFETY AND LOSS PREVENTION MANUAL FOR CONTRACTORS
I
i
FOR USE BY ALL CONTRACTOR PERSONNEL WORKING IN THE TEXAS DIVISION
l THE DOW CHEMICAL COMPANY
TEXAS DIVISION If
April. 1970 (SuperudM Safety and Lost Prevention Manual
for Contractor* dated January. 19691
i
STOOI 4 I 87
INDEX
Section
Introduction...........................................
1.0 General Safety Rule*.............................
Pre-job Safety Check Sheet............
2.0 Emergency Procedures........................... 3.0 First Aid Injuries - Reports...............
Notice of Contractor Accident or Property Loss...........................
4.0 Individual Action.................................... 5.0 Vehicles and Traffic............................... 6.0 Protective Equipment and Clothing - 7.0 Fire Protection......................................... 8.0 Machinery, Cranes, Tools and
Equipment.................................... Hoisting Equipment Inspection
Report.............................................
Hydraulic Crane Inspection Report Check List for Critical Lifts............ 9.0 Ladders and Scaffolds.............................
Safe Center Loads for Scaffold Plank................................................
10.0 Danger, Warning and Caution Tags -- 11.0 Safe Work Permits.................................... 12.0 Electrical Work........................................
13.0 Excavations, Floor Openings, Barricades......................................
14.0 Radiation.................................................. 15.0 Demolition................................................
Bkb - 4 7 -- 8
11 - 13
--15
- -16
-- 18 --22 --2S
-- 32
-- 34 --35 36-37 .. 45
- 54 - 55 .. 59 - 63
--75 --78 --79
i ii
3
!
ST00 I 4188
This safety manual contains the minimum safety -dies 'and procedures for performance of work by ontractors and their sub-contractors as required by ne Texas Division, The Dow Chemical Company, .ontractor assumes and has the full responsibility and ability for the safety of its agents, servants and moloyees and for the compliance of its sub-contracors, and anything contained herein does not relieve ne contractor of such responsibility or liability. The iaw Chemical Comoany is hereinafter referred to as Owner " The Owner will be reoresentea on contruction as defined in tne contract and neremaner eferreo to as "Owner's Representative."
Safety rules and procedures are an integral oart of acn contract and must be carried out fully, as anv trier specification for tne joD. The contractor will e neia resoonsible for ms suo-contraciors conformig with tnese safety rules and procedures. Any xceotton to tne rules set forth herein must have rior written authorization from the Owner's Repreeniative.
Contractors and contractor supervision unable or nwiiiina to secure personnel performance in keeping
/itn tnese rules will not pe acceptable. Contractc' mDtoyees wno exhibit a poor attituae toward sate vorx and safety procedures will not oe acceotaole. EMPLOYEES LEAVING A JOB DUE TO SAFET'' /IOLATIONS WILL NOT BE ALLOWED TO RE`URN TO ANY OWNER'S WORK WITHOUT PRC'ER AUTHORIZATION FROM THE OWNER. Tne -.ontractors safety record will be one criterion usee o iuane ms Qualifications tor oidainr
STOO14189
67
0*
1.5.1 Temporary buildings or combust ible materials must not be located under power lines or pipeways. Overnight park ing of equipment or vehicles under power lines or pipeways is not permitted.
1.5.2 Temporary buildings shall be sheet ed with non-combustible material, such as transite or metal siding and roof, and each must be identified with the contrac tor's name and building number.
1.5.3 Contractors' temporary buildings must be properly tied down upon place ment at the job site. A minimum of four 4-incn screw anchors a minimum of two feet in the ground are required. A mini mum of two such anchors are required for portable toilets.
1.5.4 Metal buildings served with electri city must have tne skin of the building and the service entrance switch separately grounded. Jumpers must be used, if necessary, to tie the roof and sides of the building together to insure complete grounding.
1.5.4.1 Ground rods shall be %'' minimum galvanized steel and shall be driven to a depth of 10 feet.
1.6 Contractors must furnish trash containers made of metal with metal covers kept in place.
1.7 Contractors must report immediately in writing to the Owner's Representative, by name, those employees DISCHARGED for safety rule infractions. The reason for the { discharge must be given.
j 1.8 Contractors shall maintain continuous I safety planning to cover jobs where circum
stances have changed and new hazards require new controls.
2.0 EMERGENCY PROCEDURES
2.1 The following procedure must be used to call an ambulance, report a fire, spill of hazardous materials or release of hazardous gases.
2.1.1 Dial "666" and state the type of emergency.
2.1.1.1 If the "666" number does not answer immediately, dial "O" (Operator).
2.1.2 Give your name, the nature of the emergency and its exact location, includ ing building number and door letter, if applicable.
2.1.3 Stay on the line until sure that the message is understood and confirmed.
2.1.4 Station someone on the road to direct emergency equipment to the scene.
10 li
So H
O O
-P-
K>
22 Personnel must know the location of any plant alarm horns. In case of a gas release, observe the wind direction as indicated by the alarm horn and wind vane indicator and proceed to go crosswind. STANDARD EMERGENCY SIGNALS ARE AS FOLLOWS:
2.2.1 GAS RELEASE (Continuous)
Shut down all of your equipment in operation. Stop smoking. All Safe Work Permits in that area are automatically cancelled. Personnel in other areas down wind must be alert for signals in their area or verbal instructions.
2.2.2 ALERT.................................................. (Series of short blasts)
Shut down all of your equipment in operation. Stop smoking. All Safe Work Permits in that area are automatically cancelled. Personnel in other areas down wind must be alert for signals in their area or verbal instructions.
2.2.3 EVACUATE...................... (Series of 3 short btastsl
Evacuate according to the unit emergency plan of the plant in which you are working or, lacking such a plan, observe the wind direction as indicated by the alarm horn and wind vane indicator and proceed to go crosswind or. if that direc tion is not possible, upwind.
12
2.2.4 ALL CLEAR (Series of 3 long blasts)
When this signal is given, personnel may re-enter the work area. Safe Work Per mits must be reissued prior to starting work.
2.3 If operating, a motor vehicle in an area where emergency signals are given, turn off the engine, get out of the vehicle, and be prepared to leave the area if necessary. Motor vehicles, other than emergency units, must not be driven into an area downwind of a gas release signal. Barricades across plant roads must be honored by all vehicles at atl times.
2.4 In case of fire, explosion or other emer gency. the contractor shall notify the proper Owner's Representative or his headquarters in person or by telephone as soon as possible that all employees in the area are accounted for or that specific employees cannot be accounted for.
2.5 Emergency horns are tested each Monday at 12:00 noon with the "All Clear" signal given first and last in the test cycles.
3.0 FIRST AID-INJURIES-REPORTS
3.1 The Owner's Representative shall be noti fied immediately in the event of any death, occupational disease, disabling injury or potentially significant injury to a contractor employee (whether or not it is determined that a "disabling injury" will be involved)
13
ST00I4I92
ST00I4I93
3.2.2 In the event of accidents, ambu lance runs, etc., contractors must exert all possible effort to keep onlookers from the scene. The only personnel required in such areas are those directly engaged in assisting in the emergency.
3.3 Employees must not attempt to remove foreign material from the eyes, except by washing with water. If foreign material, either solid or liquid, gets in the eye, the eye must be washed immediately with potable running water, preferably at an eyewash station, and the washing continued uninterrupted for at least fifteen minutes. It is vital that the in jured employee and others who are able to help him make sure that thorough and com plete washing of the eye is accomplished. THE AMBULANCE MUST BE CALLED.
3.4 If chemicals come in contact with the body, the affected parts must be washed with running water for at least fifteen minutes. To make sure that adequate washing is accom plished, shoes and clothing covering affected parts must be removed. The Owner's Repre sentative must be consulted before reuse of
clothing and shoes that may have been
contaminated.
4.0 INDIVIDUAL ACTION
4.1 Horseplay in any form is not allowed.
4.2 Running in the plant must be avoided exceot in case of an emergency.
is
4.3 Personnel must not climb through, under, over or between railroad cars of a train except in the performance of assigned duties necessitating such action.
4.4 Unless specifically authorized to do so by the Owner's Representative, contractor per sonnel must not make inoperative or operate safety devices such as relief valves, deluge valves, gate valves, electrical and mechanical interlocks, guards, electrical switches in an operating plant.
4.4.1 Any accidental interruption of lines or equipment in service or any irregulari ties observed must be reported to the Owner's Representative and/or the Owner's operating personnel immediately.
4.5 Unsafe shortcuts, such as walking pipe lines, sliding down pipe or stanchions and cutting corners to save a few steps, must be avoided.
4.6 Tools, materials or equipment must not be intentionally dropped or thrown from one level to another unless adequate precautions have been taken to assure that no injury to persons or damage to equipment will occur.
4.7 Lifting of personnel by a crane is prohib ited unless done by means of a bosun's chair and safety harness or by means of a crane basket and safety belt or harness.
17
ST 0 0 l L 194
4.8 Personnel must not stand, sit, walk, drop or jump on a transits roof. Where a perman ent platform or walkway is not provided, a temporary walkway or spread footing shall be used to distribute the load over a large area of the transite.
4.8.1 In lieu of using a temporary walk way or spread footing, contractors instal ling transite roofs may hang safety nets under the erection area. Such nets must be of acid resistant material, and designed and installed for the specific purpose of catching personnel who might fall.
5.0 VEHICLES AND TRAFFIC
5.1 Personnel working on Owner's property will comply with all safety rules and signs regarding traffic and vehicles at all times.
5.2 Seat belts, as required by law in vehicles, shall be used whenever a vehicle is in motion.
5.3 The maximum speed limit is 30 miles per hour on open roads in the plant and 10 miles per hour within block limits, unless otherwise
designated by signs.
5.4 When approaching a plant bus from either direction while it is stopped on a plant road to load or discharge passengers, vehicles must come to a complete stop. Provided that the way is clear, they may then proceed past the bus at no more than 10 miles per hour.
is
5.5 Smoking will not be permitted in vehicles in designated "NO SMOKING" areas.
5.6 Hauled material that overhangs the sides or ends of a truck must be red-flagged at the extent of the overhang. Loads must not be hauled from a single suspension cable that allows free swinging beyond the sides of the truck. Dragging or skidding material and objects along plant roadways is prohibited.
5.7 Fuel tanks on motorized equipment must not be filled while the engine is running or is hot, nor while welding or other hot work is being done nearby. Smoking will not be allowed in the immediate vicinity during the fueling operations.
5 Motorized equipment such as trucks, dozers, cranes, graders, etc., must not be left running and unattended.
5.9 Equipment such as welding machines, pumps, etc., shall not be transported with the engine running.
5.10 All equipment must be in safe mechani cal working condition at all times. In addition to complying with state requirements as to brakes, lights, signals, horns, mufflers, etc., vehicles must be periodically inspected by a representative of the contractor. Necessary repairs and adjustments must be made prior to their use on Owner's property-
19
STOO14195
5.11 The use of flatbed*, stakebeds, etc., as transportation for personnel will not be per mitted unless adequate safety provisions are made and the vehicle is adapted for that purpose. In any case, the number of person nel must not cause overcrowding.
5.12 Riding of "Cherry Pickers," yard cranes or winch trucks, is permitted only when adequate safety provisions such as seats, plat forms, rails, etc., are provided for passengers.
5.13 The maximum number of people who may ride in the cab of a pickup is three. Personnel riding in the back must be seated on the floor of the bed, or on approved built-in seats.
5.14 Vehicles must yield to pedestrians cross ing streets in marked pedestrian lanes.
5.15 Pedestrian paths and walkways must be used whenever provided. In their absence, personnel using streets and roadways must walk facing approaching traffic.
5.16 The following rules must be observed when moving cranes, cherry pickers, winch trucks and similar equipment having booms or extended loads in excess of 15 feet in front of or to the rear of the equipment.
5.16.1 A flagman must be provided.
5.16.2 At intersections, when the equip ment is to proceed straight across a mam
20
thoroughfare or turn either way, the operator must stop; the flagman must get off the equipment, clear all traffic, then flag the equipment through the inter section or around the corner.
5.163 Before entering any thoroughfare, street, road, etc., from a work area within a block, the flagman must clear the traf fic and flag the equipment onto the road.
5.16.4 AM booms extending more than 15 feet must be marked with high visabiiity material when moving on plant roads. Loads extending more than 3 feet in front of or behind a vehicle must be flagged. Traveling speeds must be safe and prudent, depending upon loads, traf fic, road conditions, etc.
5.16.5 A flagman must be provided and swinging of loads must be controlled with a tag line when moving in a congested area or where load swinging would pre sent a hazard to personnel or property.
5.16.6 Loads or vehicles that extend out of the normal road lanes require flagmen or escorts.
5.16.7 Contractors must check vertical clearances and bridge load limits on the route to be used prior to moving equip ment or high loads.
5.17 Prior to moving extremely heavy loads.
21
ST00I4I96
contractors must determine from the Owner's Representative which roads are to be used, and when.
5.18 Motor vehicle accidents, including those involving personal cars on company property, must be reported to Industrial Security and the Owner's Representative immediately,
6.0 PROTECTIVE EQUIPMENT AND CLOTHING
6.1 The contractor and his employees shall recognize the importance of the use of special protective equipment and clothing whenever and wherever prescribed.
6.1.1 The contractor shall be responsible for knowing and enforcing special Owner area or job rules requiring special person nel protection.
6.1.2 Contractors shall provide their em ployees with the proper protective equip ment required and shall enforce its use.
62. Approved safety glasses with approved side shields are a minimum requirement on all contractor jobs at all times and shall be properly fined to the wearer.
6.2.1 Approved safety glasses with side shields must fulfill federal requirements (GGG-G-513) for drop-ball testing and safety code for polarized "Strain" panern.
I
22
6.2.1.1 Prescription glasses with side shields are acceptable only if they meet the requirements of Paragraphs 6.2 and 6.2.1.
6.2.2 Employees wearing contact lenses must wear chemical goggles.
6.3 Chemical goggles, approved prior to their use. are required for working in or entering certain chemical areas which are posted with signs, or while doing chipping or power tool cleaning work on pressurized lines or equip ment which contains hazardous chemicals.
6.3.1 All employees working in the vicin ity of chemicals must know where the nearest safety shower and eye bathing facilities are located.
6.3.2 When chemical type goggles are in use, the headband must be around the back of the head, not around the safety hat.
6.4 Face shields, together with side shield safety glasses or chemical goggles, must be worn while grinding, chipping or buffing.
6.5 Approved plastic safety hats are required for all contractor work. The use of metal safety hats is prohibited.
6.5.1 Approved plastic safety hats must fulfill requirements in Federal Specifiea-
23
STOO 11) I 97
S T 0 0 IU 9 8
tion GGG-H-142C. The major require ment in thi* specification says, "The specimen must withstand the drop of an 8 pound spherical weight, approximately 3.8 inches in diameter, from a distance of 5 feet, without breaking the hat, bottom ing out or breaking suspension." Most skull caps, scalp guards, bump helmets, etc., will not meet this test. Safety hats shall not be drilled or punched for venti lation holes, or edges trimmed off hats.
6.6 When sandblasting or applying volatile or toxic material inside tanks, rooms or other inadequately ventilated areas, air hoods or equivalent equipment, supplied with filtered air, shall be worn.
6.6.1 The enclosed area must be suffi ciently ventilated to prevent the build-up of an explosive mixture.
6.7 Safety belts or harnesses, with lifelines attacned, are to be worn by employees when performing work in elevated positions where the use of scaffolds or ladders is impractical and where a slip might result in a serious fall.
6.8 Personnel must wear Owner approved life jackets or otherwise be protected by handrails or lifelines, when working over water wherein a drowning hazard exists.
6.9 Employees are expected to wear personal clothing that is safe and proper for their jobs.
Wearing of canvas shoes, sneakers or houseshoes, and working in an undershirt, shorts or stripped to the waist is prohibited. Loose sleeves, long watch chains or rings should not be worn where there is a potential hazard. The wearing of safety shoes is strongly recommended.
6.10 Fixed blade knives used as tools of the trade must be carried in sheaths while not in use.
7.0 FIRE PROTECTION
7.1 Accumulation of trash, oily rags, combus tible material, or fire hazards of any nature will not be permitted.
72. The area around welding and cutting operations must be kept free of flammable material of all kinds (wood, paper, cardboard, flammable liquids, etc.
7.2.1 There must be a fire extinguisher, water hose, or other fire control equip ment easily accessible for each welding, cutting, burning or other such operation.
7.2.1.1 It is the contractor's respon sibility to obtain any required fire extinguishers througn the Owner's Representative. It is also the con tractor's responsibility to arrange, through the Owner's Representative,
24
ST00 I UI 98
tion GGG-H-142C. The major require ment in this specification says, "The specimen must withstand the drop of an 8 pound spherical weight, approximately 3.8 inches in diameter, from a distance of 5 feet, without breaking the hat, bottom ing out or breaking suspension." Most skull caps, scalp guards, bump helmets, etc., will not meet this test. Safety hats shall not be drilled or punched for venti lation holes, or edges trimmed off hats.
6.6 When sandblasting or applying volatile or toxic material inside tanks, rooms or other inadequately ventilated areas, air hoods or equivalent equipment, supplied with filtered air, shall be worn.
6.6.1 The enclosed area must be suffi ciently ventilated to prevent the build-up of an explosive mixture.
6.7 Safety belts or harnesses, with lifelines attached, are to be worn by employees when performing work in elevated positions where the use of scaffolds or ladders is impractical and where a slip might result in a serious fall.
6.8 Personnel must wear Owner approved life jackets or otherwise be protected by handrails or lifelines, when working over water wherein a drowning hazard exists.
6.9 Employees are expected to wear personal clothing that is safe and proper for their jobs.
Wearing of canvas shoes, sneakers or houseshoes. and working in an undershirt, shorts or stripped to the waist Is prohibited. Loose sleeves, long watch chains or rings should not be worn where there is a potential hazard. The wearing of safety shoes is strongly recommended.
6.10 Fixed blade knives used as tools of the trade must be carried in sheaths while not in use.
7.0 FIRE PROTECTION
7.1 Accumulation of trash, oily rags, combus tible material, or fire hazards of any nature will not be permitted.
7.2 The area around welding and cutting operations must be kept free of flammable material of all kinds (wood, paper, cardboard, flammable liquids, etc.
7.2.1 There must be a fire extinguisher, water hose, or other fire control equip ment easily accessible for each welding, cutting, burning or other such operation.
7.2.1.1 It is the contractor's respon sibility to obtain any required fire extinguishers through the Owner's Representative. It is also the con tractor's responsibility to arrange, through the Owner's Representative,
24 25
Q
for the recharging and resealing of extinguishers immediately after each use.
ii
72.12 When such work is being done in a grassy area where an ade quate water hose is not available, mops and buckets of water shall be kept on hand for the control of possible grass fires.
722 Special care must be taken during overhead cutting and welding operations to safeguard personnel and prevent falling sparks from starting a fire. Warning signs must be posted at each level below the area of any overhead welding, burning or cutting operation. Warning signs are avail able through the Owner's Representative.
7.22 A Safe Work Permit must be ob tained prior to cutting or welding along or above a railroad right-of-way. A blue flag must be placed on the track if sparks or slag could constitute a fire hazard to passing railroad cars. In the event it be comes necessary to remove the flag and move rail cars, the Safe Work Permit is
cancelled and must be reissued before the work is resumed.
72.4 When rail cars that contain combus tible or flammable material are within 50 feet of the work area, they must be moved prior to starting any hot work.
26
72 All tarpaulins shall be fire-retardant and identified as such by stenciling: "FR-treated (date)** with a minimum of 2-inch fetters in diagonal corners. In lieu of this treatment, fire-proof blankets such as fiberglass or asbes tos are acceptable.
72.1 Contractors must inspect and test ail tarpaulins at least once each six months to be sure that they are still fire-retardant.
72.1.1 Tarpaulins passing the test must be re-stenciled to show the date of the test.
7.3.12 Tarpaulins failing the test must be removed from the Owner's property immediately. They may be returned only if re-treated, re-tested, approved and re-stenciled.
7.4 Fire protection must not be impaired by unauthorized use of. or interference with, fire protection equipment.
7.4.1 Fire hydrants, fire hose racks, ex tinguishers and other emergency equip ment shall not be covered or blocked.
7.42 Access lanes for fire fighting equip ment must not be blocked by unattended contractors' equipment after working hours. During working hours, contractors must be able and ready to clear access roads and fire lanes at any time.
27
STDO 11* I 99 "
7.4.3 Tie-ins with hose or piping shall not be made on any sprinkler system or monitor nozzle.
7.4.4 The hose on fire-hose racks is for emergency use only and shall not be used as service hose.
7.4.5 Temporary hose connections may be made to fire hydrants only if other water supply is not available, the tie-ins have been approved by the Owner's Fire Department through the Owner's Repre sentative, and such connections are re moved at the end of each work period (except in cases where a special waiver is granted by the Fire Department).
7.5 All heating units for offices, shops, work areas, change rooms, etc., must be in good working order and periodically inspected. Gas units must be provided with "flame-out" protective devices and electrical units must be grounded. Gas units shall not be connected by means of rubber hose. All heating units must be turned off at the end of each work day.
7.6 Flammable or explosive type material such as fuel, oil, cleaner, etc., must be pro perly contained, clearly identified, separately stored and kept clear of work areas. Appro priate warning signs must be provided in storage areas.
2B
7.7 All containers used for transporting or transferring gasoline or fuel must be labeled by Underwriters' Laboratories or Factory Mutual Laboratories.
7.8 Fuel storage tanks, filler hoses and the dispensing vehicle or container must be pro perly grounded, and be equipped with con tractor furnished fire extinguisher. Storage tanks must be identified with the contractor's name.
7.8.1 A quick closing shut-off valve is required on the dispensing end of fuel noses.
7.8.2 Smoking, welding or any spark-or flame-producing operation in the imme diate area must be stopped during refuel ing operations.
7.8.3 The Contractor shall provide and maintain "NO SMOKING" signs in fuel storage areas.
7.9 Welding rod cabinets presenting a fire or safety hazard will not be permitted. Cabinets of fireproof materials equipped with strip heaters are recommended. If light bulbs are used, they must be securely guarded with adequate spacing in relation to the cabinet and to stored material. Metal cabinets must be grounded in an approved manner.
7.10 Volatile materials must not be applied near an open flame or in inadequately venti-
29
STOOi4200
STOOIU20I
lated areas. If such material is to be applied in a vessel, or other confined area, only explosion-proof connections, lights or other equipment shall be used. The contractor must designate such areas as "NO SMOKING."
7.11 Heating equipment for freeze protection of concrete must be approved by the Owner's Representative prior to use.
7.12 Welding or cutting torches and hoses must not be left connected to cylinders when stored at the end of the work day. When work is shut down and equipment is un attended, close all valves at the gas and oxygen cylinders, bleed lines and check five minutes later for pressure build-up. If there is no build-up, bleed hoses at the torch, remove hoses from cylinders and store. No smoking will be permitted during this shutdown pro cedure.
7.13 Gas and oxygen cylinders must be handled with care, properly supported in an upright position away from any source of heat or flame and securely tied off. All cylinders not in use must have their caps in place.
7.13.1 Oxygen cylinders stored in build ings shall be separated from fuel-gas cylinders or combustible materials (esoectally oil or grease) a minimum distance of 20 feet, or by a non-combustible oamer at least 5 feet high having a fireresistance rating of at least one-half hour.
It
7.13.2 Oxygen cylinders stored outdoors must be separated from fuei-gas cylinders a minimum distance of 10 feet or by a fire-resistant barrier.
7.13.3 When gas and oxygen cylinders are lifted by hoisting equipment, a basket, cradle or similar handling device must be used. Cylinders must not be lifted by the valve protection caps.
7.13.4 When oxygen or gas cylinders are transported by any means over plant roads, valve protection caps must be in place.
7.14 All "NO SMOKING" restrictions in spe cified areas must be strictly observed. Smok ing is not permitted in vehicles in designated "NO SMOKING" areas.
7.15 Compressed gases, including air, must not be used for cleaning of clothes, the body or work areas. Oxygen must not be used for pressure testing purposes.
7.16 Adequate ventilation must be provided when cleaning agents are used.
7.17 Contractors must not dump flammable or toxic materials into sanitary sewers or waste water system without prior clearance of the Owner's Representative.
31 30
8.0 MACHINERY, CRANES. TOOLS, AND EQUIPMENT
8.1 Th safe design capacity of any tool or piece of equipment must not be exceeded. Tools or equipment must not be modified in any manner that reduces the original safety capacity.
8.2 All contractor owned, leased or rented equipment must be in safe mechanical work* ing condition to render safe service at all times.
8.2.1 Defective tools and equipment must be removed from service immediate ly and, if repairable, must be properly repaired before reuse on Owner's job.
3.3 Equipment with exposed gears, belts, couplings, fans, etc., must be provided with proper guards.
i.
8.3.1 Machinery, tools and equipment
must not be operated without all guards and safety devices in place and function ing properly.
8.4 All cranes, including hydraulic cranes (cherry pickers, pole cats, bucket trucks, etc. I must be inspected by the contractor and ap proved by the Owner on a regular frequency of four months. Crane inspections must be submitted in writing to the Owner's Repre sentative. using the Owner's "Hoisting Equip ment Inspection Report" or "Hydraulic Crane
32
Inspection Report" form, whichever is applic able (see samples on following pages!. Equip ment must be shut down before repairs or adjustments are made. Each inspection report will be audited by the Owner and, if ap proved, a numbered and dated decal will be affixed in the cab of the crane. Except as noted in Paragraph 8.4,1, no crane without the proper decal affixed is to be used on the Owner's property.
8.4.1 The Owner's Representative shall visually check each crane prior to initial use on a job to assure himself that it is satisfactory for use on the job at hand. The Owner's Representative may give temporary permission to use the crane pending the completion of an inspection and audit, provided, however, that a criti cal lift (see Paragraph 8.4.3) is not in volved and that the inspection/audit pro cedure is initiated immediately.
8.4.2 All "bucket trucks" or "pole cats" must be ground tested before lifting personnel. During use, a standby man must be ready to take over controls in case of an emergency.
8.4.3 The contractor has the complete responsibility for a safe operation when using hoisting equipment to make lifts. The contractor shall verify weights of loads to be lifted. No load shall be lifted which exceeds the Manufacturer's rated
33
ZOZ'llOOlS
34
802*1 tOOlS
oucx utr for critical urn
lit&Mt/UftlM
L JM BMPlITIflil
OATS.
* IflOATtOM
---- ---------
4 00W REPRESENTATIVE
t fuiwim DATA:
A 1.
...
1 mmiiwittiiir
X tUPERVtSQR ftCVONSItLt FOR UFT__ a MKAimON OF ITEM TO B8 RAUIO -- - -
C MAJOR MOISTING EOUWMtNT TO BE UllO (MUTT INCLUDE UdPfCTION TAO HO. AND OATf. TAGS ARC VALID FOR FOUR MONTHS.!
0. EOUIPMENT AMO LIFT RELATIONSHIP
t. QRtRATtRQ RAHtLlC
_
i Tmu t tMflTM
_
X ALLOWABLE LOAPIFROMLOADCHART).
4. RATIO OF LIFT TO ALLOWABLE L0A0 __
ft. CLEARANCE IETWEEN BOOM ANO LIFT __
t CLEARANCE TOSURROUMOtNO FACILITIES
E. SCHEDULE OF OPERATIONS (INCLUDE TIME FOR RIQCINO ANO EQUIPMENT INSPECTION).
. BARI PON CRITICAL LIPT:
A LOAD EXCEED* BO* OF LOAD CHART FOR CRANE OR DERRICK _
1 tOAO EXCEEDS 10* OF LOAD CHANT. ANO FAILURE WOULD
ENDANGER BXISTINO facutih_
-- ------------
a TWQfcftfljHAtMtflUIBIfl
0. POLES OR DERRICKS HAVE SEEN ERECTED FOR THIS VtCtFtC LIFT--
7. HOW W1IOHT OF CRITICAL LIFT WAS ORTAINtO: A CERTIFIED SCALE WEIGHT__________________
36
CALCULATED IN0CPENOCNTLT BY MORE THAN ONI SOURCE. I. source_--__________ f<ant,
X SOURCE
.WEIGHT.
IF LIFT IS AN EXISTING ITEM (RClNG REMOVED OR OCMOUSHEOI. THE WEIGHT IS TO IE RECALCULATED. TAKING INTO ACCOUNT ALL MODIFICATIONS INCLUDING INTERNAL AS WELL AS AN ALLOWANCE FOR SCALE. SEDIMENT. SLUDGE. INSULATION. UQUIO. ETC.
1. SOURCE.
.WEIGHT.
2. SOURCE .
-WEIGHT .
A CONDITION OP NOtSTINO EQUIPMENT ANO RMGtttQi
A. HAS EQUIPMENT iCCNRftNSPfCTtO FOR THIS LIPTT
a HAS ALL IOUIPMCNT ANO RlGQING SEEN INJECTED ANO FOUNO
IN ACCEPTABLE CONDITION FOR THU LIFT?
a GUY ANCHORS ANO GUVS:
A. AQtOURgVOPFOUNOATlQNORRrtQTLQglf-------
S ADEQUACY. NUMBER. ANO LOCATION OF GUVS ANO ANCHORS___
C FOOT BLOCKS ARg TO BE AWCHOBKn, _ _ __________
a CONDITION OF ALL CABLE. (NCLUOlNQ SPUCES CLAMP!
THIMBLES, ANOOTHIR HARDWARE
___
la TABILITY OF OROUNO AREA: A PMECK Mm. REARIMQ ALLOWABLE LOAO
B. WILL MATS BE REQUIRED? _ __________________________________ C. ANY UNDERGROUND INSTALLATIONS NEEDING SPECIAL
TBEATMEWT
11. OPERATORS:
WHAT IS OPERATORS EXPERIENCE ON THIS EQUIPMENT AND THIS
TYPE OF LIFT? _
__________
IX REMARKS
i el a CHECK LIST t* Be
mkv Mr *wrmn
v:.
Resuvi OF ACTUAL 8CNEDULE:
TJfli
OATE OF LIFT
INSPECTIONS COMPLETED_____________
LIFT STARTED________________________
PERMANENTSUPPORTS COMPLETED__
TOTAL TIME __________________________
37
STOOIU204
1&-
ST00I4205
capacity of the crane. When one of the following conditions prevail, the contrac tor must, using the Owner's "Critical Lift Sheet" (see sample), submit a written outline of the safety planning for the lift to the Owner's Representative, prior to starting the lift.
a. The load exceeds 80 percent of rated load chart for crane.
b. The load exceeds 50 percent of rated load chart for crane, and possible failure would endanger existing facilities.
c. Two cranes are required to make the lift.
d. Poles or derricks have been erected for this specific lift.
8.4.4 If burning of lugs or other such flame producing operations may be re quired during crane hoisting operations, arrangements for proper Safe Work Per mits must be made before the lifting or burning operation begins.
8.5 The following rules must be observed when operating a crane, cherry picker, winch truck or similar piece of equipment.
8.5.1 A flagman must be provided when ever equipment in operation partially blocks a plant road or whenever else operation of the equipment could present a hazard to personnel or property.
as
85.1.1 Personnel shall be kept out from under any load being lifted.
8.5.2 When mobile equipment (cranes, draglines, cherry pickers, winch trucks, etc.) is used near overhead power lines or O.C. bus bars, the fallowing listed safe working distances shall be observed:
a. Five feet minimum clearance--circuits up to 480 volts. (Telephone wires and telephone cables are not hazardous but must not be contacted or damaged.)
b. Eight feet minimum clearance--480 volts to 2,400 volt circuits, open wire unprotected on insulators--O.C. power lines and bus bars--15,000 volts shielded or armored power cables on messenger cables in pole lines.
c. Sixteen feet minimum clearance15,000 volts and 132,000 volt bare (uninsulated) bus in 132 KV substations and conductors on 132 KV power lines. When it is necessary to work over or under a power line or D.C. bus or within tne above listed minimum safe working distances, it shall be the contractor's responsibility to notify the Owner's Rep resentative prior to performing any work. This is not intended to restrict electrical work performed by linemen.
8.6 All pressure vessels of construction equip ment must be hydrostatically tested annually. Items in this category are those exceeding 6
39
8.6.2 Relief valves must be removed and the vessels hydrostatically tested to one and one-half times the maximum allow able working pressure of the unit. A thorough visual external inspection must be made.
8.6.3 As a part of these test procedures, relief valves must be properly sized ana set for the vessel involved and checkeo for proper ooeration. apart from tne vessel test.
8.6.4 Metal identification tags must be attached to relief valves bearing oressure setting, date of test, name of company
conducting test and name of person con ducting the test.
8.6.5 Contractors will furnish the Owner's Representative a test certificate for each piece of equipment. Each certifi cate must be signed by the test conductor and a representative of the company owning the equipment.
8.6.6 The Owner's Representative wili forward each certificate to the & CZ Construction Department Central Office. B-2402, where an eauioment numoer will be assigned and the certificate wilt be kept on file. The contractor will be informed of the assigned numoer ov ine Owner's Representative.
8.6.7 Contractors shall paint or stencii the assigned equipment number in olain view on the equipment. The numerals shall be painted or affixed on a colored background. They shall be approximately 3" high and of a color contrasting witr the background color. The oacxarounc color for the calendar year 1970 shall oe yellow. The background color will oe changed for each calendar year thereafter, and contractors will oe notified ir. December as to tne color for tne follow ing year.
STO0|!i2O6
8.7 Electrical tools and equipment operating at more than 32 volts must be properly grounded. Certain test equipment such as oscilloscopes, vacuum tube voltmeters and signal generators, as well as certain areas where exposed O.C. equipment is used, do not require grounding and proper operational procedures must be ascertained from the Owner's Representative in the above areas. Electrical office equipment and coffee pots shall be grounded.
i
8.8 Lacking buttons on electrical tools must be removed or otherwise rendered inoperative.
8.9 Only 32 volt or less electrical service is to be used when working inside metallic vessels. Drop lights shall have protection guard over globe. Transformers must be kept outside vessels.
8.10 When arc welding is to be done, the grounding lead should, to minimize the possi bility of intermediate arcing, be connected as close as practical to the work piece.
8.10.1 When arc welding is to be done in an area restricted by a Safe Work Permit, the grounding lead MUST be connected to the work piece within the limits specified in the permit.
8.10.2 All leads and lead connections
shall be in good condition and free of any exposed conductors.
8.11 Gloves must not be worn while using pedestal or bench mounted grinders, drills, saws or any toots where gloves are apt to become entangled.
8.12 Loose clothing must not be worn while working around machinery.
8.13 Personnel must not crank any machin ery with their feet.
8.14 Hose connectors and adaptors must be of a standard manufacture and used only for the type of service intended.
8.14.1 In order to insure positive locking at all times, hose connectors must be in good condition and not abused. Sand blast hose connections shall be the safety lock type which prevents accidental dis engagement.
8.14.2 Spring-loaded snap-on "Cleco" quick hose connections must be reserved for use on air and cold (under 140 F.) water hoses only. A part of the "Cleco" connector must not be left connected to a process line or equipment.
8.14.3 "Boss-type" union connectors must be used on steam and hot (140 F and above) water hoses.
STOO14207
\
802*1 i 001S
#- #' # 4
8.14.4 Air pressure on pneumatic tools must be bled down before tools are disconnected from air supply.
8.14.5 Care must be exercised not to allow air hoses to come in contact with steam lines or hot equipment.
8.15 Powder-actuated fastening guns shall be used only in accordance with the following procedure.
8.15.1 Whenever it is planned to use such equipment on a job, the Contractor's Representative shall submit to the Owner's Representative:
a. Written notice of intent to use such equipment.
b. A written safe work procedure cover ing use of the equipment, and
c. The qualifications of the men who will use the equipment.
8.15.2 The Owner's Representative shall, if satisfied with the submitted procedure
and the qualifications, give the Con
tractor's Representative written permis sion to proceed.
8.15.2.1 Use of the equipment shall not be allowed until sucn written permission is in hand.
9.0 LADDERS AND SCAFFOLDS
9.1 All ladders must be in good condition and of the proper length for the job at hand.
9.1.1 Wooden ladders are not to be painted with anything other than clear paint or linseed oil. All metal parts must be hot dipped galvanized.
9.1.2 All straight ladders must be tied off or held and stepladders higher than ten feet must be tied off at the top or held at the bottom by another workman. Per sonnel must not stand on the top step of any stepladder.
9.1.3 When climbing a ladder, personnel must face the ladder and keep both hands free for climbing. Where practice!, grasp ladder by side rails, rather than the rungs.
9.1.4 Set straight ladders so that the bottom is out from the vertical about one-fourth of the distance from the upper support to the bottom.
9.1.5 All straight ladders must be pro vided with non-skid adjustable feet.
9.1.6 The area around the bottom of all ladders must be free from slippery sub stance and tripping hazards.
9.1.7 All wooden ladders must be stored
9.2 The use of No. 9 soft annealed wire is not recommended and its use should be minimiz ed on scaffolds.
9.2.1 When the use of No. 9 soft anneal ed Wire IS absolutely necessary, a mini mum of two separate stranas must be used to tie scaffold handrails, braces, etc. The ties must be crossed to form a lock and prevent slipping in any direction.
9.2.2 Do not reuse No. 9 soft annealed wire ior any purpose.
9.3 Makeshift scaffolds such as "Coke" boxes, crates and drums must not be used.
9.4 Wood-framed scaffolding, aluminum lad
ders, aluminum scaffolds and aluminum pencil c/5
boards are not permitted except in special __ \
cases as specified in job specifications or by f-->
prior written approval from the Owner's <--3
Representative.
__
9.S The following rules apply to all patented DO
metal scaffolds.
O
<X> 9.5.1 Scaffolds must be erected with
proper fixtures made for each type of
scaffolding. Scaffolds and associated
equipment must not be modified in any
manner that reduces the manufacturer's
designed performance.
9.5.2 All scaffolds and oppurtenances must be kept in good repair.
9.5.3 Equipment that is damaged or de teriorated to the extent that it is unsafe snalt not be used. Such equipment shall be removed from the Owner's property.
9.5.4 Compensate for unevenness ox ground by using adjusting screws in addi tion to proper blocking.
9.5.5 Do not force braces to fit. Adjust evenness of scaffold until the proper fit can be made with ease.
9-6.2 Towers of a height greater than tnree times the minimum base dimension must be guveo or tied off while being erecied, used or dismantled.
9.6.3 Caster brakes must be applied wnen not in motion.
9.6.4 Extreme care must oe exercisec wmle moving a rolling scaffold.
9.6.4.1 Towers must be tree of men
9.6.4J2 Surface are* where tower is being moved shall be free of rubble or any material that may cause the tower to tip.
9.6.4.3 Oo not attemDt to move a roiling tower without sufficient help.
9.6.5 Oo not extend adjusting screw? beyond the limits specifiea ov tne equip ment manufacturer.
9.6.6 The minimum size for casters shal' be 6 inches. Scaffolds higner than 25 feet must be stabilized, eitner with outriggers or hand lines, while being movec.
9.6.7 Horizontal diagonal bracing is to be used at tne bottom and at intermediate levels of 30 feet.
9.6.8 Do not use knee braces or canti levered brackets on rolling towers.
9.7 The following rules apply to susoenaeo scaffolds:
9.7.1 Chains or Vi-incn (minimum i steel cable snatl be usea to support susoendec scaffolds. All suspended scaffolds shall oe ancnored to prevent swinging. Chains so used shall be maoe of not less tnan %-incr, links' and shall be insbected immediate!v
prior to each use. Chains shall be securely fastened by the use of double wrapped No. 9 wire through the links or fastened with e stove bolt.
Safa Load Limits for Scaffold Chains
1/4" proof coit loading chain, proof test* ed to 2350 lbs. Safe Load - 1175 lbs.
5/16" proof coil loading chain, proof test ed to 3500 lbs. Safe Load 1750 lbs.
9.7.2 The suspending support must be insulated when arc welding is to be per formed from platform, thus avoiding acci dental arcing and subsequent failure.
9.7.3 Block and falls, if required, shall be a minimum of two sheaves for 3/4-inch rope and the minimum size rope shall be 5/8-inch. Acid resistant rope shall be used in acid or caustic areas. Tail ropes shall be placed in an open container for protection while used in an acid area or above operating machinery, pumps, etc. All ropes and blocks must be inspected and tested prior to each use and taken down and stored inside at the end Of each
work day.
9.8 The following rules apply to ail scaffolds:
9.8.1 Scaffolds and related material shall be carefully inspected at regular intervals and particularly just before using.
9.8.2 Scaffold boards shall be used exclu sively for work platforms.
934 Provide sufficient sills or under pinning on all scaffolds to ba erected on filled or otherwise soft ground. Scaffold boards shall not be used for this purpose.
93.4 All scaffolds must be plumb and level at all times.
933 All scaffolds shall be guyed or tied off at every IS feet of elevation. Anchor running scaffolds to wall approximately every 28 feet of length. Use additional care when using pulley arms.
93.6 All work levels of a scaffold must, if practical, be fully planked. If, of neces sity, a work platform is not completely planked, personnel working on that plat form must use property tied-off safety belts.
9.8.7 Handrailing and access ladders must be used on all scaffolds regardless of height. Scaffolds higher than 30 feet around columns, tanks, etc., must have access ladders constructed on the inside, unless a ladder cage is provided. Hand rails must be at a height sufficient to provide maximum personnel safety.
9.8.8 Scaffolds must not be used as material hoist towers or for mounting
derricks without first determining the loads and stresses involved.
9.8.9 Erect scaffold in such a manner that ladder is easily accessible and lined up from top to bottom.
9.8.10 Lumber used in the construction of platform shall be of good quality and reasonably straight grained. It shall be free from injurious ring shakes, checks, splits, cross grains, unsound knots, knots in groups, decay and growth characteris tics which materially decrease the strength of the lumber. Planking shall not be painted all over, as this would conceal any defects. Scaffold boards shall be identified by painting each end. When wooden handrails are to be installed, nothing less than 2 x 4-incn (nominal) material shall be used for the purpose.
9.8.11 The normal size of planking shall be determined from Table 1. These values are for planks with the wide face up, with the loads concentrated at the center. Loads given in the table are net. Allowance has been made for tne weight of the planking. If select structural coastregion Oougias Fir or mercnantable struc tural square and sound southern pine is used, the loads may be increased 45 percent.
9.8.12 Planks used for olatforms shall be
52
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of uniform thickness, laid close together. These planks must be overlapped at the bearers. An overlap of at least two feet must be allowed with the bearing in the center of the overlap. When planks over hang a bearer more than one-tenth of the length of the span, the planks must be securely fastened to the bearer at the opposite end to prevent tipping.
9.8.13 All nails used in scaffold construc tion shall be driven full length. If double headed nails are used, they shall be driven to the first head only and may not be used on platforms or walkways. No nail smaller than 8d shall be used in this con struction and enough nails must be driven to support the designed loads. The design must be such that no nail is subject to a direct pull.
9.8.14 Where beams are used in scaffold ing, the schedule of loads shown in Table II, shall be followed. Loading on canti lever type beams used for tool and material hoists is shown in Table III. It should be noted that the loading at the center of bearing point is four times as great as the load being lifted and the bearing should be checked to ascertain if
it will support the contemplated load. The inboard end of the beam has a force upward of twice the load and must be securely fastened with no nails in direct oull.
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9.8.1S Platforms shall be kept dear of slippery substances and tripping hazards.
9.8.16 Scaffolds shall ba so erected that any heated pipelines or equipment will not come in contact with wind breaks or scaffold boards.
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10.0 DANGER, WARNING AND CAUTION TAGS
10.1 Danger Tags (Redl
10.1.1 To insure that operating status of equipment is not changed while it is being used or worked on. Red Danger Tags must be attached to the controls.
10.1.1.1 No control such as a valve, switch, clutch, etc. is to be operated by anyone while a Red Oanger Tag is attached.
10.1.1.2 Red Danger Tags must not be altered or used for more than one job.
10.1.1.3 if a control must be oper ated intermittently such as for test ing equipment, the Red Danger Tag must be properly removed before
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each operation. The Red Danger Tag may be reused on the same job if the ecope of the job has not changed.
10.1.1.4 Violation of Red Danger Tag rules will result in disciplinary action up to and including rejection from any work on Owner's property.
10.1.2 Attachment of Red Danger Tags to equipment controls does not mean that equipment has been cleared to work on. When work is to be done on tagged-out equipment, personnel responsible for the operation of the equipment are respon sible for clearing the equipment and making it safe for others to work on.
10.1.3 Whenever the operation or use of any equipment may endanger anyone, a request must be made to supervision of the group which operates the equipment to clear and tag the equipment. "Clearing" means making the equipment inoperable and safe for others to work on. The authority to clear and tag equipment
may be delegated by this supervision to
any qualified personnel after supervision has assured themselves that the person delegated can properly dear the equip ment for the particular job involved.
10.1.4 After the group which operates the equipment has cleared and tagged the eduipment. eacn worker or group of workers who may be exposed to the
hazards must tag the equipment for their protection. When Red Danger Tags are attached to equipment by persons other than those responsible for its operation, prior approval from the person respon sible shall be obtained.
10.1.5 As the individual jabs have been completed, each worker or group of workers must remove their tags imme diately.
10.1.6 The group responsible for the equipment must place their tags first and remove their tags last.
10.1.7 Red Danger Tags may be removed only upon authorization of the person designated on the tag, except in the fallowing specific instances. The super visor of any person who fails to remove a Red Danger Tag when a job has been completed may authorize the removal of the tag by another person in his organiza tion after he has determined to his com plete satisfaction that the equipment can be operated in a safe manner. Authori zation across line organizations is not permissible except for those cases where Section 10.1.5 ("As the individual jobs have been completed, eacn worker or group of workers must remove their tags immediately.") has been violated and no supervision in the violating organization is in the plant. In such cases, the Operating Department supervisors must contact
STOOI 42 11,
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supervision in the violating organization to obtain authority to remove the tag. The Operating Department supervisor must first determine that the equipment can be operated in a safe manner and that all non-operating workers have left the immediate area, in the space on the tag entitled, "Removal will be ordered hy " It is permissible to designate some classifications, such as foreman, electrician, pipefitter, etc., in* stead of a special individual's name.
10.1.8 At the discretion of the super visor, locks may be used on valves and switches in addition to, but not in place of Red Danger Tags.
10.1.9 Tags removed must be filled out and turned in to the Owner's Representa tive. I, 10.2 Warning Tags (Green)
10.3.1 White Caution Tags are affixed to mechanical or electrical equipment by the Owner's Representative to prevent inservice operation of such equipment by anyone until items on the tag have been completed.
10.3.2 The tag provides spaces for meggering, rotation, final alignment and lub rication of equipment. When appropriate action has been taken, then personnel performing the work signs and dates the tag.
10.3.3 When tagged equipment is releas ed to the Owner, a representative of operations and the Owner's Representa tive sign the tag which is kept by the Owner's Representative until job comple tion.
11.0 SAFE WORK PERMITS
10.2.1 When it is necessary to convey instructions or information prior to oper
ation of equipment controls. Green Warn
ing Tags are to be attached to the co' -.rols.
<0.2.2 Green Warning Tags should be removed when conditions set forth on the tag have been met.
10.3 Caution Tags (White)
11.1 Safe Work Permits issued by the Owner to contractor personnel are required for cer tain hazardous locations and conditions. These permits are designed to provide a means of checking at the job site the safety of such jobs as, but not limited to. entering dosed vessels; working on electrical gear; performing hot tap work; welding, cutting on, breaking into or repairing pipelines or vessels in opera tion or under pressure or that have contained hazardous materials. These permits also cover work involving the use of flame or spark pro ducing equipment in hazardous areas, near an
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open ditch, or for work on machinery.
11.1.1 Safe Work Permits are specifically required for any excavation work done with machinery (gradails, draglines, augers, pile drivers, ditching machines, etc.). These can be obtained only with the approval of the Owner's Representa tive and after he has completed a pre scribed Safety Clearance for Machine Excavation.
11.1.1.1 "Excavation" is defined as tne penetration, in any manner, of the grouno.
11.2 Contractor supervision must be in close contact with tne progress of work and must be in constant communication with tne Owner's Representative for up to date status of operations. Further, contractor super vision must be certain tnat all personnel in volved are informed as to specific procedures and changes in the situation.
11.3 Safe Work Permits are to be initially re quested tnrougn the Owner's Representative and issued by the Owner's operating area or
facility supervision involved on any job wnere
the Safe Work Permit is applicable. More tnan one Sate Work Permit may be required on certain joos which will be ascertained uQon obtaining each Safe Work Perm-.*..
11.3.1 Safe Work Permits will be issued ontv after a physical cneck of tne job site by tne person issuing tne permit
11.4 Personnel must give a careful ana eomDiete aescriotion of tne work to oe aane tc
the person issuing the Safe Work Permit.
11.4.1 Where a job presents a serious man hazard, it is mandatory that a written Safe Job Procedure accompany the request for the Safe Work Permit. If, on jobs of a repetitive nature, it is necessary to nave a written procedure, one that is already written will do in lieu of writing one if the contractor says he can follow the procedure and do the job safely. New procedures are to be signed by the Manu facturing Representative, tne Owner's Representative, and the Contractor's Representative. If previously approved procedure is to be used, it must be
initialed and dated by the above-named representatives.
11.5 Directions and restrictions noted on Safe Work Permits must be carefully followed.
11.6 A Safe Work Permit must be revoked and reissued for a job if mere is evidence that conditions have changed subsequent to the issuance of tne original Safe Work Permit.
11.7 Permits issued for jobs tnat last longer than one day will normally be issued for that job eacn day. By mutual consent of the oarties involved, permits for mese jobs mav be issued for longer or snorter periods of time.
11.8 Existing vessels to be entered must be maoe safe tor personnel.
STOOI 42 I 6
11-8.1 Tha requirements set forth in the following tub-paragraphs must be accompiished by the Owner before entry of any personnel is permitted.
a. Vessels to be entered must be isolated by blinding or disconnecting from process and service systems. Double block and bleed may be permitted if the foregoing methods are impractical.
b. Hazardous materials contained in the vessels and related piping must be remov ed or reduced to a safe level by washing, steaming, or purging.
c. Tests must be made with an approved combustible gas indicator to detect the presence of any flammables.
d. Tests must be made with an approved oxygen indicator for excess or deficient oxygen content.
11.8.2 A Safe Work Permit must be ob tained.
11.8.3 Rescue breathing apparatus, test ed just prior to entry, must be on hand nearby on the outside of the vessel.
11.8.4 Whenever personnel are working inside a closed vessel (one entered through a manhole), an attendant must be stationed outside one entrance to warn of external danger or summon help if needed.
62
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11.9 A Safe Work Permit shall be obtained before working on pipelines or other equip ment which contain or have contained hazard ous material.
11.9.1 The proper protective clothing and equipment (slicker suits, face shields, full-face gas masks, chemical goggles, rub ber gloves, etc.!, as specified in the Safe Work Permit, must be worn.
11.10 Prior to any welding or burning, either inside or outside, on an existing vessel, the vessel must be positively checked inside for flammable or explosive gases or liquids, and a Safe Work Permit must be obtained before heat is applied.
11.11 The contractor may request Safe Work Permits for his own protection. Safety checks by the Owner for dangerous gases or chemi cals should be requested through the Owner's Representative, when there is any uncer tainty. 11.12 Atl Safe Work Permits in the area affected are automatically cancelled when an emergency signal is sounded and must be reissued after the "Atl Clear" signal. 12.0 ELECTRICAL WORK
12.1 Work on energized electrical equipment shall be minimized and if such work is found to be necessary, it shall be given sufficient careful planning to protect personnel from electric shock and flash burns and all other foreseeable hazards.
63
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12.1.1 Electrical equipment of 460 volt* (nominal) or more, or equipment of lest than 460 volts that is protected by a (use or circuit breaker of 100 amperes or mora, shall not be worked hot unless and until the Owner's Representative has re ceived a written Safe Job Procedure from the Contractor's Representative AND has obtained the written approval of the Major Production Manager(s) and the Major Service Group Managerial in whose ireeU) of responsibility the work will be performed, and then it shall be done only by personnel specifically qualified for this type of work.
12.1.1.1 The following jobs are exempt from this "hot work" policy.
a. Trouble shooting on control cir cuits of 460 volts or (ess which are isolated and protected -by a fuse or breaker of 30 amps or less.
b. Work on equipment with nominal voltage levels of 230 volts or less which is isolated and protected by a fuse or breaker of less than 100 amps.
c. Checking of fuses.
The use of proper shock protection equipment, such as rubber gloves, fuse Dullera. hot sticks and insulated tools, shall be required on any such work.
12.1.2 IF ELECTRICAL EQUIPMENT
&4
OF ANY VOLTAGE CAN NOT BE DE ENERGIZED. AND THE PROPOSED WORK ON IT CAN NOT BE SAFELY DONE HOT, THE WORK SHALL NOT
BE-ROMS.
122 Procedures for Working on 115/230 Volt Equipment.
122.1 The Contractor'! Representative shall request permission from the Owner's Representative to work on the equip ment.
1222 If it has been decided that the equipment is to be de-energized for the work, the Owner's Reoresentative shall arrange with the Manufacturing Repre sentative for the equipment to be de energized.
1222.1 The Manufacturing Repre sentative, or his designee, shall de energize the equipment, attach hit Red Danger Tag to each disconnect ing device involved, and then issue an Electrical Safe Work Permit to the Contractor's Representative.
12222 The Contractor's Represen tative, or his designee shall, with a voltage indicating device, confirm that the equipment is de-energized and then attach his Red Danger Tag to each disconnecting device redtagged by the Manufacturing Repre sentative or his designee.
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12J2^ It th equipment can not be de energized and can safely be worked hot, the Contractor's Representative, or his designee, must obtain an area Safa Work Permit from the Manufacturing Repre sentative, or his designee, before proceed ing with the work. This permit shall be issued only upon presentation of a pro perly drawn up and approved Safe Job Procedure (See Paragraph 11.4.11.
12L2.3.1 Equipment, instruments, tools, barricades and protective clothing (See Paragraph 12.7) to be used shall be noted in the written Safe Job Procedure.
12.3 Procedures for Working on 460 Volt Equipment.
12.3.1 The Contractor's Representative shall request permission from the Owner's Representative to work on the equip ment.
12.3.2 If it has been decided that the
equipment is to be de-energized for the
work, the Owner's Representative shall arrange with the Manufacturing Repre sentative for the equipment to be de energized.
12.3.2.1 The Menufacturing Repre sentative. or his designee, shall de energize the equipment, attach his Red Danger Tag to each disconnect
66
I
ing device involved, and then issue an Electrical Safe Work Permit to the Contractor's Representative.
12.3.2.2 The Contractor's Represensentative. or his designee, shall, with a voltage indicating device, confirm that the equipment is de-energized and then attach His Red Danger Tag to each disconnecting device redtagged by the Manufacturing Repre sentative, or his designee.
12.3.2.3 When a visible check can not be made tor verification of open disconnects or disconnected leads on the 460 volt supply source, grounds shall be applied to the system. When grounds ere to be installed, this in formation shall ba noted on asso ciated Red Danger Tags. Upon com pletion of the job, the grounds shall be removed before the Red Tags ate detached.
IF IN DOUBT. GROUND IT!
If grounds are needed but can not be installed, the work shall be perform ed as if the equipment is energized (See Paragraph 12.3.3).
123.2 If the equipment can not be de energized and can safely be worked hot, the Contractor's Representative shall pre pare a written Safe Job Procedure and submit it for approval by the Owner's
67
9
ST00I4220
Representative, the Manufacturing Repre sentative, the Major Production Maneger(s) ANO the Major Service Group Managers) in whose area(s) of responsi bility the work will be performed. Only upon presentation of a properly approved Safe Job Procedure shall the Manufactur ing Representative, or hit designee, then issue an area Safa Work Permit to the Contractor's Representative, or his designee.
12.3.3.1 Equipment, instruments, tools, barricades and protective clothing to be used shall be noted in the written Safe Job Procedure.
12.3.3.2 The Contractor's Represen tative must be present during the entire job, and if the geographical area of the work makes close obser vation bv one man impossible, addi tional non-working supervisors must be assigned to assist him.
12.3.3.3 Immediately prior to com
mencing work, the Contractor's Re
presentative and the Owner's Repre sentative shall conduct a safety meeting to review the Safe Job Pro cedure with the personnel assigned to the job.
12.4 Procedures for Working on or in Close Proximity to 2400 Volt and Higher Voltage Eauipment.
es
12.4.1 The Contractor's Representative shall request permission from the Owner's Representative to work on the equip ment.
12.4.2 if it has been decided that the equipment is to be de-energized for the work, the Owner's Representative shall arrange with the Manufacturing Represen tative for the equipment to be de-ener gized. The following procedures shall then be followed.
12.42.1 Equipment under the con trol of the Utilities Department Power Dispatcher (Includes ail Elec trical Distribution facilities of 2400 volts or higher voltage!.
12.4.2.1.1 The Manufacturing Representative, or his designee, shall obtain a Power Dispatcher's order to de-energize the equip ment. He shall then proceed to carry out the order, attaching a Power Dispatcher's Red Danger Tag to each disconnecting device involved. This having been ac complished, the Owner's Repre sentative shall obtain a clearance from the Power Dispatcher to proceed with the job. The Manufacturing Reoresentative, acting for the Power Dispatcher,
shall then issue an Electrical Safe Work Permit (ESWPI to the Con
69
tractor's Representative. The Clearance Number shall be noted on the ESWP and the ESWP Number shell be given to the Power Dispatcher by the Owner's Representative.
12.4.2.2 Equipment NOT Under the Control of the Utilities Department Power Dispatcher.
12.4.2.2.1 The Manufacturing Representative, or his designee, shall de-energize the equipment, attach his Red Danger Tag to each disconnecting device invol ved, and then issue an Electrical Safe Work Permit to the Con tractor's Representative.
12.4.2.3 Following receipt of the Electrical Safe Work Permit, the Con tractor's Representative, accompani ed by the Owner's Representative, shall check the protection applied, attach his Red Oanger Tag to each disconnecting device tagged by the Manufacturing Representative, and test each piece of equipment to be worked on with a voltage indicating device to prove that it is de-ener gized.
12.4.2.4 Except as noted below, grounds shall be applied in all cases.
70
12.42.5 Grounds may be omitted in the case of single-ended 2400 volt to 4160 volt circuits, such as motor circuits, where disconnecting devices can be visibly checked and locked out and attachment of grounds is so difficult as to be impractical. Omis sion of grounds must, however, be agreed to by the Manufacturing Re presentative, the Owner's Represen tative and the Contractor's Represen tative. In such a case, the equipment shall be considered "hot", and pro cedures for hot work shall be follow ed.
12.42.6 The location of grounds applied to 15 KV shielded power cable conductors is critical in many instances in relation to the maximum safety of workmen. Grounds shall be applied ONLY as specified by the Owner's Representative.
12.4.2.7 When grounds are to be applied, the Power Dispatcher shall be so notified and the fact noted on the Electrical Safe Work Permit and the Clearance. Upon completion of the job, the grounds shall be removed before the Red Tags are detached.
12.42.8Red Oanger Tags authoriz ed by the Power Dispatcher shall be removed only with his permission.
71
122*11001$
12.4.3 IS KV and higher voltage equip ment shall not be worked hot.
12.4.4 If 2400 >4160 equipment can not be de-energized and can safely be worked hot, the Contractor's Representative shall prepare a written Safe Job Procedure and submit It for approval by the Owner's Representative, the Manufacturing Repre sentative, the Major Production Mana gerial AND the Major Service Group Manager(s) in whose area(s) of responsi bility the work will be performed. Only upon presentation of a properly approved Safe Job Procedure shall the Manufactur ing Representative, or his designee, then issue an area Safe Work Permit to the Contractor's Representative, or his designee.
12.4.4.1 Equipment, instruments, tools, barricades and protective clothing to be used shall be noted in the written Safe Job Procedure.
12.4.4.2 When work is to be per formed on equipment under the con trol of the Utilities Department Power Dispatcher, the Owner's Rep resentative must notify the Power Dispatcher just prior to commencing work. With the Power Dispatcher's permission. Yellow Work Tags shall be attached by the Manufacturing Representative, or his designee, and the Contractor's Representative to
72
any relayed or fused device that will open should a fault occur during the course of the job. The purpose of these tags is to prevent redosure until the fault has been corrected and personnel moved out of danger.
12.4.4.3 The Contractor's Represen tative must be present during the entire job, and if the geographical area of the work makes close obser vation by one man impossible, addi tional norvworking supervisors must be assigned to assist him.
12.4.4.4 Immediately prior to com mencing work, the Contractor's Rep resentative and the Owner's Repre sentative shall conduct a safety meet ing to review the Safe Job Procedure with the personnel assigned to the job.
12.4.4.5 Before work is commenced, ground fault indicators, if any, shall be checked and any existing fault corrected.
12.4.4.6 If the Power Dispatcher is involved, the Owner's Representative shall notify him of the completion of the job and obtain permission for the removal of his Yellow Work Tags.
12.5 On jobs involving work on energized
73
ST00I4222
electrical equipment, the contractor shall fol low the approved Safe Job Procedure faith fully.
12.5.1 If, during the course of a job, any minor deviation from the approved Safe Job Procedure should be deemed neces sary or advisable, the Contractor's Repre sentative shall obtain the written approval of the Owner's Representative and the Manufacturing Representative before pro ceeding. Should the proposed deviation be significant, however, the written approval of all signers of the original Safe Job Procedure must be obtained before proceeding.
12.6 Voltage indicating devices used to con firm the de-energizing of circuits or equip ment shall be tested and proven operable immediately prior to and after use.
12.7 Yellow barricade tape or other approved methods of barricading shall be used to pro tect personnel from open energized electrical equipment of 50 volts or more.
12.8 Protective Clothing
12.8.1 A fire-resistant plastic face shield witn hood and flash protective clothing, consisting of 10 oz. "Nomex" jackets and oants or full-length coat, must be worn as outer garments under certain conditions, as follows:
a. When working on any energized 230 volt equipment or circuit that is protected at more than 100 amps.
b. When working on any energized 460 volt equipment or circuit that is protected at more than 30 amps.
c. When working on or within reach of any energized 2400 volt or higher equip ment or circuit that is not electrically shielded or mechanically protected.
12.8.1.1 Linemen may be exempted from wearing a face shield and hood and flash protective clothing if they are not handling energized facilities in a confined location. This exemp tion must be stated in, and approved as part of. the written Safe Job Procedure.
12.8.2 Rubber gloves shall be worn whenever installing or removing grounds as specified in Paragraphs 12.3.2.3 and 12.4.2.4.
12.9 With the exception of the 138 KV Sub stations, smoking shall not be permitted in Power Distribution substations.
13.0 EXCAVATIONS. FLOOR OPENINGS. BARRICADES
13.1 Where a safety hazard would be created for the personnel involved, and/or others.
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excavations such as ditches, trenches, or bell holes should be slooed sufficiently to prevent cave-ins or slides. If sloping is impractical, shoring must be used in cases wherever the vertical dimension exceeds four feet.
13.1.1 Personnel removing shoring after completion of work must not be in the bottom of the excavation. Shoring must be removed in such a manner to prevent cave-in on personnel.
13.2 Contractors must provide adequate barricades, covers, handrails, signals, flagmen, or other appropriate warning devices to pro tect personnel near any hazardous operation or excavation. Floor openings, open trenches, excavations, etc., shall be covered when hand rails or barricades do not provide adequate protection to personnel.
13.2.1 Contractors must notify the Owner's Representative of necessary ob structions on road shoulders on the day such obstructions occur.
13.2.2 Contracrors must obtain approval
from the Owner's Representative at least one day prior to cutting roads or other wise obstructing traffic on plant roads.
13.2.3 All barricades must be nonored at all times.
13.2.4 When tne necessity for barricades
76
no longer exists, they shall be removed immediately.
13.3 Grade lines, ropes, chains, and other tripping hazards must be sufficiently marked to be clearly visible day or night.
13.4 No obstruction of any kind, whether permanent or temporary, is permitted within 8*9" horizontally from the centerline of any railroad track and within 22'6" vertically from the top of the rail.
135 In locations where strictly temporary loading or unloading operations are to be undertaken, blue flags and portable derails available through the Owner's Representative, must be used to prevent over-running of the work by a train. Blue lights, also available through the Owner's Representative, must be attached to blue flags at night. Placement of blue flags and portable derails must have prior clearance with the Owner's Representative, who will in turn obtain clearance from the
Railroad Department.
13,5.1 Blue flags/blue lights must be placed on the tracks so thev will be in unobstructed view of the train crew and they must be placed a minimum of two car lengths (100 feetl in front of the area they are intended to protect. Exceptions to the minimum distance may be made by the Owner's Representative where exist ing installations do not allow sufficient space.
\ 13.5.2 Blue flags and portable derails must be removed immediately when the hazard for which they were installed no longer exists.
I 13.6 Specific authorization from the Owner's Representative as well as the proper placing of blue flags, blue lights and portable derails is required prior to boring under or excavating adjacent to railroad tracks when passage of a train would create a hazard for personnel or equipment.
14.0 RADIATION
14.1 All state and/or federal laws governing use. storage or handling of a radiation source must be complied with.
14.2 A minimum of two qualified people are required for the performance of any radiographic work.
14.3 In locations where a radiation source is used or stored, regulations require that it be marked with a "Radiation Material" sign. This sign is for the purpose of informing anyone in the area that such material is present, and not that a safety hazard due to radiation exists.
14.3.1 Only authorized personnel may enter an area marked by "Radiation Area" sign,
14.3.2 All areas wnere a radiation hazard
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exists must be roped off all the way around the area and marked conspicu ously by standard signs at a safe distance from the source of radiation. These signs bear the radiation symbol of magenta (or purple) on a yellow background with the words "Caution--Radiation Area."
14.3.3 "Radiation Area" signs must be removed when a radiation hazard no longer exists in the affected area.
14.3.4 Equipment containing a source of radiation must not be handled, uncrated or installed without prior clearance with the Owner's Representative.
15.0 DEMOLITION
15.1 Due to the inherent hazards in demoli tion work, soecial care must be devoted to safe procedures, scope understanding and communications concerning tne safe clearance of work.
15.2 Responsibility for field supervision of demolition work must be delegated only to those whose exoerience qualifies them to make the necessary judgments and decisions that are required to assure the sarest possible prosecution of the job.
15.3 The contractor shall make certain that all lines, services and equioment have been cleaned or purged and properly cleared for sare removal. All lines lincludmg water and
STOOP-* 225
ft O
Q
steam) arc to be considered "hot" until positive sate clearance has been obtained. 15.4 Special care shall be exercised to locate and mark old underground or otherwise hid den lines, cables and sewers using the best available information and Owner's assistance. 15.5 The pre-job safety meeting with the contractor, as covered in Section 1 of this manual, shall devote special attention to pre-planning the safety aspects of demolition jobs.
15.5.1 Steps of dismantling and loads to be handled shall be reviewed with the Owner's Representative prior to starting work. 15.5.2 Temporary provisions must be made where safety showers, eve wash baths and fire extinguishers are being moved in the work area. 15.5.3 Special attention shall be given to the marking of hazards and the barricad ing of hazardous areas for the protection of all personnel, including those not directly involved in the demolition work.
STDOI 4226
T "2 V; 17- a -
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THE DOW CHEMICAL COMPANY
Midland, Michigan C
)
DOW CONFIDENTIAL
June 24, WO
ST0000703
TO WHOM IT MAY CONCERN:
It was my privilege to attend an intensive course on asbestos at Mount Sinai Medical School in New York last week. In the accom panying report, a brief attempt has been made to summarise this learning experience.
I have innumerable references available, including 11S 35-mm slides, of ail aspects of the course and would be pleased to discuss any aspect in detail with you or a group of your choice. Lists of the slides and references are attached.
i have purposely kept my summary short, but can enlarge un any particular area if you are interested.
,/
U\/ ' / lA Uu i /< / /)
Charles G. Kramer, M.D. ' Corporate Medical Department
ASBESTOS AND HEALTH
Asbestos is an extremely useful mineral in our society--having more than 3, 000 different applications.
Early in this century, a scarring disease of the lungs called "Asbeslosis"
was discovered. Control standards were established and, to my knowledge,
no case of ''classical" advanced asbestosis has occurred at our Company.
This disease brought early death, usually in less than ?.0 ye
after first
exposure.
"
Though there is no reason to believe we have ever exceeded the timeweighted average recommended for control of asbestos-containing dusts, it has now become apparent that these people exposed to the lower levels will develop various other forms of "asbestos disease" after a lapse period of . 20 to 30 years. These diseases consist of
(1) thickening of'the pleura or lining of the lungs,
. (2) cancer of the lung, (3) cancer of the gastrointestinal tract, and,
(4) malignant mcsolheliomas--a deadly cancer of the
^
. ' lining of the lung or abdomen which is extremely rare
except following asbestos exposure.
CD
`
-CD
Studies by our Medical Department indicate that, though we thought our ^
* employees were exposed only to safe levels, the changing opinion of what
* constitutes a safe level has'left us with a significant number of individuals
who are potential victims of asbestos disease. We should therefore
(1) institute procedures to minimize future exposure, . , (2) institute medical surveillance of the individuals at risk, and,
(3)'institute a campaign among the previously exposed group to discontinue smoking, which habit vastly enhances the chances of developing cancer of the lung.
Some Divisions have ongoing control programs of excellent quality and I have no doubt their people will gladly share their, experience with anyone who has not yet established control.
Continued public information on this topic could eventually result in .another case of environmental hyslcria--we hope if such occurs we can say everything that can be done has been done. Eel us be sure that, in addition to controlling our plant environment, we also insure that wc arc adding no asbestos dust to the community environment.
Corporate Medical Department July 17, 1970
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ST0000704
cc
THE DOW CHEMICAL COMPANY
MIDLAND DIVISION July JO, 1970
Harold Eosscher, Manager Midland Division 47 Building
SUMMARY ON ASBESTOS IN TIE MIDLAND DIVISION
Since the recognition of health hazards associated with the use of asbestos, the following steps have been taken.
Environmental Health conducted a study of pipe covcrerc on the job and determined the exposure to dusts from insulating materials in use. By determining how long and how often the various activities were performed a time-weighted exposure was established. From this information, the minimal respiratory protection was established for each type of insulating material ana each activity in the pipe eoverers job.
During August, 1969 the results of this study were presented to the pipe eoverers, maintenance supervisors and production representatives. Additionally, the Medical Department explained the health hazards involved and the effects of smoking as a habit which enhances the chances of developing cancer of the lung. The maintenance group explained whaz would be required for respiratory protection and when it was to be worn. The use of fiberglass as a replacement for aircell was discussed.
Since August, 1969, the use of aircell has been discontinued and replaced with fiberglass (100l'7 - J50CF). Carey temp 1500 has been introduced as the replacement for calcium, silicate type insulations up to IbOCf'P. Purchasing will not buy an insulation containing asbestos without notifying the Maintenance Technology Center anti insuring that there is no other material that will do the job. Careytemp is more difficult to work with and install than com.? of the calcium silicate insulations. Because of this, there is probably a 9 to lot extra cost in using Careytemp. As the eoverers become more experienced with Careytemp, this should drop. Work ir. underway with the manufacturer to improve the product.
ST0000705
ilarolu jk.sseher
Frosent technology docs not give us a si.;bfah Lute for asbestos at high tempcrataror. (i-ISoc"!'. ). Ceramic foam " may offer a possibility for high temperature use. Insulating cements are also a problem area. Until substitutes can be developed, careful handling procedures must be followed during the mixing.
The introduction of additional ashes to:; containing insulation Into the Division lias boon vastly reduced. In the coming years, the prime source of asbestos exposure will be the removal, transportation and disposal of old asbestos insulation. Procedures for-handling anu sending old insulation to disposa] must be developed.
The other major use of asbestos is in the chlorine cell maintenance area in the manufacture of diaphragms for chlorine cells. The asbestos is received in 50 lb bags and dumped into a mix tank. About J50 lbs is required for a diaphragm for the present cells and ''-50 - 500 lbs will be required per diaphragm in the new plant. The new plant will use about 50,000 ibs/yr of asbestos for this purpose.
The operation has been studied by Environmental Health and the proper respiratory equipment has been specified for the mixing operation. In the old cell maintenance area only full bags of asbestos arc bandied and use of partial bags is avoided which reduces exposure. The mixing is an intermittent operation which also reduces personnel exposure. The new plant will have a complete ventilation system above the mix tank which wi.31 go to a filter unit and then to a scrubber or bag filter.
In the cell buildings asbestos is handled in small amounts by the operators. It is dumped directly into the cell to plugholes in the diaphragm. This operation requires respiratory protection. For the long term solution, a new material of construction for diaphragms is being considered but a likely successor has not yet been found.
In the cell maintenance area as the old diaphragms are washed with high pressure water, 70,5 of the ar/ocstos is recovered on a set of vibrating screens and is cent to land fill. The remainder is recovered at the treatment plant on the centrifuges.
Environmental Health is making ?. complete inventory of uses of asbestos and recommended disposal techniques. The Maintenance Technology Center will work with Waste Disposal and Environmental Health to develop procedures for handling and disposal of covering,.
--(h J
Vf. A. Snodgrass Maintenance Technology Center 85,l Building
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T r X A S IlIVtSION' FftecportT irxAs ttsm
September 11, 1970
B. J. Kinscl B-108
cc: 0. A. Easton
. ASBESTOS INSULATION - STATUS REPORT
,
_
As of tlie date of this report, the Insulator Shop has discontinued the j installation of most asbestos-bearing pipe insulation. In cases where the service requirements are greater than 1500F., we are still installing Kaylo 20, a calcium silicate, asbestos reinforced material. This use is limited, mostly, to tube-turns on LIIP cracking furnaces. This work only comprises about 27, of the jobs we currently install. This is expected to continue until an adequate high temperature substitute is found.
All of the Kaylo, a calcium silicate asbes tos-filled insulation for temperatures to 1200*F. , has been removed from the shelves in the shops . and has been returned to locations as directed by Stores. Hie field stocks are being shipped to Stores as they are located. It is felt that approximately 807. of these field stocks have been removed to date. Ue are still in the process of locating and eliminating these small amounts
of material.
`
I
Engineering standards of E & CS and Texas Division are in the process of
being revised. It is felt that finalization of these standards will take
about eight weeks longer. Contractors are still being allowed to install
Kaylo and Kaylo 20 on new construction although' most of the new instal
lations are in Carey-temp, a non-asbestos material.
. *
*
Technical Development is working in the area of finding substitutes for .materials which contain asbestos such as transite, haveg, etc.
It is felt at this time that existing safety rules regarding the use of respirators for. "hazardous dusts" are adequate to require the use of respirators by all personnel when dismantling the existing insulation materials. Subsequent to additional talks with.the Safety Department,a
we expect to formally communicate with all supervisors involved. 'The cd Functional Superintendents have already talked with the Zone Superin- co tendonts regarding the use of respirators, when handling these products.
.
We had some minor difficulties with Purchasing's getting us into the -- Carey-temp business, but these were ironed out quickly. I feel that. we are .now "over the hump" .as far as the change over occurs. There are a great many loose ends which still need to be gathered up. I will keep you informed as we change specifications, types of materials, handling
procedures, etc.
F. B. Crouch
/wb
ASBESTOS USAGE - STATE OlN MAINTENANCE DEPARTMENT AT* .'lUibfc.fi a ' ~ " Briefly, we feel that the highest exposure rates are experienced by "'a Insulator Group which handles the material on a day-in and day-out sis, both maintenance and construction. The next highest group would be
the Brickmasons who apply the loose asbestos fill used in the mag pot program. Next in the exposure-time-weighted factor would be the persons who occasionally fabricate asbestos-bearing materials such as transite, haveg, and the like. The last on the exposure list would be those persons who occasionally perform demolition of asbestos-bearing insulation within the plants such as removal to facilitate repairs, etc., and handling loose material torn off existing lines prior to sending to the dump grounds.
Presently, we have discontinued all purchasing of asbestos-bearing insulating pipe covering with exception of certain selected sizes of Kaylo 20, a high temperature pipe covering material, used for temperatures from 1200F to 2200F. Only use we are aware of for this material is certain
Lght hydrocarbon plant furnaces tube-turn bends. We have made a concerted effort to eliminate the small stocks of
asbestos pipe covering which are scattered throughout the division. I believe we have accomplished this goal to the tune of about 95% complete We have also returned all asbestos pipe covering from our supplier (Gulf Supply) back to the manufacturer.
Presently, we believe' that only about 2% of the insulators* work within the division is made up of asbestos pipe covering. ($4,000 to $5,000 to eliminate all existing stocks.)
Insulating materials we are using to replace asbestos are: 1. Fiberglass - both in Msnap-on'* and loose blankets, ambient to 350F. 2. Foamglass - 450 to 800F - also used where temperatures cycle excessively and for Dowtherm service. 15% more expensive than asbestos.
S T 0 0 0 2 .8 1 8
ST00028I 9
'V. ^ .
3. Careytemp 1500 - ambient to 1500F - expanded pearlita fiberglass reinforced. Some problems associated with application but best available at present. Same cost as
asbestos. Several other areas we are working on:
1. Have problems with loose fill insulation used when setting mag pots. This generates a terrific amount of dust when asbestos shorts are used. We have found that "Super 48" by "48 Insulations, Inc." mineral wool makes less dust than asbestos shorts and contains only about 10% asbestos. The texture is slightly damp or moist feeling, thus cutting down on the dust problem. When our brickmasons are using this material, they have been wearing respirators. . We have been assured by the manufacturers of "Super 48" that .by October 16 they will be producing an asbestos-free insulation in bags marked as such. The composition of this material is a mineral wool made from copper slag. -
2. Fabricating of asbestos-reinforced plastics such as transite, haveg, micarta, where dusts become a problem in operations such as sawing and grinding. We have no problem with insulators wearing respirators, when this work is going on. Saws have been developed with vacuum systems to reduce
%
.amount of dust, but we still wear respirators as we still get quite a bit of residual dust. ' 3. Our foremen have been notified that respirators are to be worn by the employees when significant amounts of Insulation are to be removed when demolition occurs. We have not yet made it a firm rule to wear respirators in any'situation where dusts of asbestos occur, but I believe this will be only a short time before we do. Due to gathering evidence
V of existing hazards.
v.,
The last principal area X want to cover is that of new construction.
We are currently in the process of changing the Texas Division
standards which will require the elimination of Kaylo (asbestos-type pipe
covering) from the list of approved material. The donstruction Department
is continuing with all new construction in asbestos in which the material
is on 'the job site, but any other new work will have the Carey temp 1500
or expanded pearlite installed in lieu of asbestos. This change.took place
about the 5th of October. This is a* brief summary of where we stand in the Maintenance program
of elimination of asbestos exposure hazards.
STO O O 202O
F. B. Crouch /bs October 13, 1970.
V ----- V. ASBESTOS USE - STATUS OF IN TEXAS DIVISION
$
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.We recently ran a survey of the use of asbestos in the Division with the object of answering 3 questions - 1) Where is asbestos used 2) What protective gear is being used and 3) What have people been told about asbestos.
Where is asbestos used? In addition to the use of asbestos containing
i<v*avjLvt'iiM O
materials/vt^atcdhsve^beensused throughout the Division, asbestos is used in our chlorine areas for cell diaphragms in cell manufacturing, and repair for facilities and in all chlorine plants for.pulping cells. Asbestos is also used in the Hag Cell areas for insulationin pot settings and in numerous other ways for the sealing of leaks in the cells and vent systems.
In addition to the use of new asbestos, we also have the problem of tearing out of insulation throughout the plant as well as the dis posing of used asbestos in the chlorine and magnesium areas.
There is also in use materials of construction such as transite and haveg that are asbestos containing materials.
ST000282I
What protective gear is being used?
*
In most of the areas where asbestos is being used, either installed or disposed, we now have some form of protective gear in use. Our insulators have been wearing respirators for sometime. Cell Manu facturing folks have had a good protective program for about the last 1% to 2 years. Recently the Mag folks started using more pro-
V V. tective gear. I would say that the insulator and Cell Manufacturing and repair .people have a good program with good supervisory control. With some of the other crafts who occassioualy remove and dispose asbestos materials, the use of protective gear is variable, probably relative to the degree of exposure. Contractors in the Division presently do not wear much in the way of protective gear.
What have people been told?
Asbestos information which our folks have received varies widely. Some have been, told little, if anything -- others that asbestos is' hazardous to the lungs -- and others that it causes lung problems including cancer. Probably the best informed are those who have been under the periodic examination program where the doctors have apparently discussed asbestos candidly. Contractors probably have been told little about the hazards of asbestos.
Now, I'll turn this over to Jack Crouch who will discuss the effort by the Maintenance folks.in substituting some different materials for asbestos containing materials.
RCW/ks 10/14/70 S & LP
ST0002822
V
ASBESTOS RECOMMENDATIONS
I'. Develop a Dust-Asbestos informational type program for division employees and contractors. (Similar to other hazardous material programs which have been developed.)
2. Develop and audit safe work procedures for minimizing the generation of asbestos dust. Procedure must include protective gear as a final precaution.
3. Continue to pursue the replacement of asbestos with reasonable economic substitutes. (Recognize that asbestos is probably irreplaceable in certain applications.)
4. Develop procedures for accounting for asbestos used and in tnorfitoring asbestos exposures.
5. Continue periodic physical program oh division employees who have reasonable exposure to asbestos.
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STOOI ti361
October 27, 1970
0* L. Dlclcson
0. N. Freeman J. H. Moore R. L. Silverthorne
cc: J. A. Barton R. E. Flake, M. D.
B. S. Horvath
BUST - ASBESTOS SAMPLING
*. I have asked Jack Barton to set up to pm Dust-Asbestos Sampling training program. I would like each o you to go through this training. It is the intent that you become qualified to make dust-asbestos surveys. Jack thinks that it will take about 6 half days to.do this. Training will' be Monday, Wednesday, and Friday afternoons, starting at 12:30 Friday, October 30, 1970, in Jack Barton's office.
T consider this to be high priority and hope you do not miss any of the training sessions.
ks attachment
(.aT-
.
R. C. Walker Safety and Loss Prevention
STO O 14362
0
DUST SURVEY (ASBESTOS^ PERSONNEL TRAINING OUTLINE
1. Develop Background A. Research the Literature - Tox. B. Talk with Dr. Flake - His viewpoint and Dow workers clinical evidence. C. Research sample and analysis techniques.
2. Set Up Equipment In Lab - Dry Run
m
3. Set Up Survey at Cell Manufacturing, etc. and Get Samples 4. Have Samples Analyzed - U.S.P.H.S. Method 5. Evaluate Date and Write Technical Report
JAB/ks 10/27/70 S 6c LP
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DUST RESPIRATOR USAGE
^AI2?t-)AL|
The following safety rule will, be placed in effect with Maintenance Department employees on November 2, 1970.
All Maintenance Department employees sub ject to hazardous dusts such as silica, asbestos, etc., must wear an approved dust respirator. Areas where sandblast ing and demolition of existing insulation for the purposes of salvage and/or repair would be included in this rule.
The two respirators which have been approved by the Safety
Department are: (1) MSA Dustfoe 77, Dow Stock No. 15-26005, Cartridge No. 15-23775, and (2) Wilson Dust Respirator, Dot? Stock No. 15-25460, Cartridge No. 15-23790.
You should see that your people are notified and equipped
for this prior to the effective date.
.;
F. B. Crouch /bs
All Contractors E & CS Construction Department Personnel - Freeport
DUST RESPIRATORS
The following safety rule will go into effect on November 9, 1970:
All contractor employees subject to hazardous- dusts'such as silica, asbestos, etc., must wear an approved dust respirator.
Areas where sandblasting, demolition, etc., of such materials are involved are included in this rule.
Two respirators which have been approved for thisVservice are:
1. Dustfoe 77, MSA No. 96000, Cartridge MSA No. 96077
2. Wilson Dust Respirator (Mask) No. 600A, Cartridge Wilson
No. R-501.
C
You should see that your people are notified and equipped with the approved respirator prior to the effective date.
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CHEMICAL CO M PAN Y
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T t * A 1 C I v i l *i *. Tt*AI /M4t
November
1970
C. li. Harding, Jt. ".agnesLuia X .\-o50
cc: K, C. Walker, B-101
ENVIRONMENTAL CONDITIONS AND PROTECTIVE EQUIPMENT SPECIALIST TEAM NOVEMBER INSPECTION 0? KACNF.S1UN I
A^ide from the obvious problem* of hear and gas exposure agninst which you seem to be waging t continoing battle the Specialist Teats feels you r.wy be overlooking two problems.
I. .vsbessTis exposure: occurs with mixing of dry asbestos: replacing m\J breaking up asbestos pane La and tearing -tsbearus sheeting. We recommend A) An intensive educational program Informing the men of risk of the danger of lung cancer with asbestos exposure combined with cigarette smoking.
9) Strict enforcement of adequate protection when ex posed to asbestos dust: 1) Acme-Duo Seal with clip on dust filter or 2) Welsh twin cartridge respirator with clip on Uusc
iliter (elcher of which will be effective against ..t.t'Slnc dust ami ciilurl.nO .
l. Woi.Se (};-.....appeals co be . ptoblr.v*
A) Ceibnn hanging - air uriven tools
b) Air driven chipper - cleaning cells
a
C) Me cal transfer crew - motor noise. We recommend
1) Noise level measurements L.i nbove areas by the
Inuustrial Hygiene group,
1') Mandatory car plugs in th^se ...ear where acceptable
muse 'evel is exceeded.
.v. >,/.> i'r..
l<. K, PIt.Ne,
J.tl (For the 1pe.c Lu Li aC Team)
THE DOW Cl
axd (i(ju^
HOUSTON DOW CENTER Texas Division November 10, 1970
H. L. Mathews - Angleton D. M. Turner - Freeport - A-1201 J. E. Arbour - Houston J. P. Murray - Bay City W. G. Specht - Bay City J. C. Brownfield - Houston T. C. Mandrell - Houston W. R. Hale - Freeport-B-101
HAZARDOUS DUST
You are aware that effective November 2, 1970 all employees subject to hazardous dust, such as silica, asbestos, etc., must wear approved dust.respirators. Mr. Bergen has issued the same safety rule for all contractors and E&CS Construction Department personnel.
You are advised to instruct your personnel of this rule which also applies without exception to our people and our contractors.
R. R. Swanke APC Chairman
lo
NOV 1 g 1970
' C. f.'AN'DSP '
NOV 1 21970
606119015
V--^
HANDBOOK
FOR
HANDLING ASBESTOS MATERIAL
THE DOW CHEMICAL COMPANY TEXAS DIVISION
Maintenance Department Supporting Services March, 1971
3T0540027
SAFE WORK PROCEDURE
Subject: Insulation Removal
Minimum Safety Equipment Requirements
1. Hard Hat must be worn.
2.. Side Shield Goggles must be worn.
3. Approved "Nose and Mouth" Dust Respirator must be worn at all times.
4. A Safety Check List is to be filled out prior to the job and properly approved. Turn in to supervisor at completion of job.
5. All other safety equipment which is required by job location must be used. When in doubt, read Area Safe Work Procedure.
Special Hazards:
1. Do not breathe asbestos dust.
2. Asbestos dust falling or blown on other employees and scattering throughout the area must be eliminated as far as possible.
3. Keep all personnel not directly involved in the Insulation removal operation away from the area unless they observe minimum safety requirements and have been apprised of the hazards involved.
4. Consider the use of water to wet down the insulation before and during removal.
5. Safe handling of all debris before loading at the job and unloading at the burial site is to be considered and planned for prior to the initiation of the job. The Yard Department is to be notified for disposal, informed of the hazards, and should handle material while still in a damp condition.
10 -
ST0S40037
USE OF HANDBOOK FOR
HANDLING ASBESTOS MATERIALS The Safe Work Procedures outlined in this handbook are minimum requirements for working with asbestos containing materials.
In some cases, job conditions may dictate more stringent requirements. These could include completely wetting down the area with water when removing old insulation, or completely isolating the work area tarpaulins, etc.
These procedures are to be used in conjunction with Plant Safety Rules, Maintenance Standard Safe Work Procedures for the Area, and Safety Standards.
-A -
ST054003I
V *
HANDBOOK FOR HANDLING ASBESTOS MATERIALS
Index
Page(s)
1. Purpose and Description
2
2. Safety
3
3. Use of Handbook
A
4. Safe Work Procedures
Fabrication of Asbestos Materials
5,6
Mixing Cement ContainingAsbestos
7
Handling and Storing AsbestosMaterials 8
Sawing and Cutting by Hand
,9
Insulation Removal
10
5. Pre-Job Check List
11
6. Threshold Limit Value
12
% c/>
CD,
cn
XT.
o
CD
PO,
CO
-1- "
m
PURPOSE AND DESCRIPTION
The purpose of this handbook is to outline the safe handling procedures of various asbestos materials used in the Texas Division. The intent is to minimize future exposure of employees to asbestos dust in any form through the proper use of safe work procedures. Asbestos is widely used as structural Wall board, insulation, and roofing material. Asbestos fibers are used as a mechanical reinforcing matrix in insulation, roofing paper, certain piping systems, etc. When working with materials which contain asbestos fiber, care must be taken to eliminate as much loose dust as possible. Wetting, Isolating the work area, or other suitable procedures to eliminate the dust hazard is absolutely necessary. Should a hazard exist and these procedures are not sufficient, contact the superintendent of the Plant A or B Functional groups. Exceptions to these procedures can be obtained only .by the above responsible superintendent.
-2 -
6300*1 SLOtS;
SAFETY
Materials described herein are furnished in blocks (or lags) shapes, curved segments, pre-formed pipe and fitting covers, flat and corrugated sheets and the asbestos as loose material.
When handled, formed, cut, sawed, or mixed into mortars, a fine dust will be loosed in the air which may be breathed into the human respiratory system.
The health of those who breathe asbestos dust may be seriously effected. Results can be similiar to those caused by the more commonly known materials such as silica and coal dust. This phenomena has been observed for many centuries. Current medical discoveries show that handling of asbestos by a confirmed cigarette smoker is especially hazardous in the area of potentially serious lung disorders. It is recommended that those persons handling asbestos not smoke cigarettes in any quantity.
The intent of THE DOW CHEMICAL COMPANY is to minimize the exposure of their employees to these hazardous . dusts. In order to accomplish this, substitutes will be used wherever possible. Respiratory protection, dust collectors, blowers, etc., will be mandatory where asbestos containing materials must be handled.
The two respirators which have been approved by the Safety Department are: (1) MSA- Dustfoe 77, Dow Stock No, 15-26005, Cartridge No, 15-23775, and (2) Wilson Dust Respirator, Dow Stock No, 15-25460, Cartridge No. 15-23790.
-3-
"ST 0540030
SAFE WORK PROCEDURE
Subject: Fabrication of Asbestos Materials
Minimum Safety Equipment Requirements:
1. Side Shield Goggles must be worn.
2. Approved "Nose and Mouth*' Dust Respirator must be worn at all times.
3. There shall be a Dust Collecting System on Power Equipment adequate to remove large amounts of dust generated.
4. A Safety Check List is to be filled out prior to the job and properly approved. Turn in to supervisor at completion of job.
Special Hazards:
1. Do not breathe asbestos dust.
2. Do not operate equipment if provision eannot be made to eliminate dust in a safe manner.
3. Normal precautions must be taken for working with power equipment. (See specific Safe Work Procedure for Operating Power Driven Tools if in doubt.)
4. When cleaning out the vacuum system of the machines, a respirator must be worn. Wet down dust prior to handling, if at all possible. Dispose of asbestos dust while in a wet condition. The Yard Department must be notified under these circumstances and disposal by landfill should be accomplished while material is damp,
5. Good housekeeping in the shop area is to be practiced. Asbestos dust must be vacuumed throughout the shop area if and when such conditions exist.
ST054Q032
-5-
(More)
SAFE WORK PROCEDURE Fabrication of Asbestos Materials Page 2 Special Hazards Cont'd. 6. People in area other than worker when exposed
to asbestos dust are required to observe all minimum safety requirements.
-6-
ST0540033
SAFE WORK PROCEDURE
Subjec&: Mixing Cement Containing Asbestos
Minimum Safety Equipment Requirements:
1. Side Shield Goggles must be worn.
2. Approved "Nose and Mouth" Dust Respirator must be worn at all times.
3. A Safety Check List is to be filled out prior to the job and properly approved. Turn in to supervisor at completion of job.
Special Hazards:
1. Do not breathe asbestos dust.
2. When mixing whole sacks, do not open sacks and dump into open mixing tray. Moisten asbestos by adding water through a small hole in sack until danger of dust is eliminated. Then the material can be removed if necessary to complete mixing operation to desired consistency.
3. Slipping or falling is a hazard to be considered when working around wet asbestos mud.
4. Back strains from handling containers of mixed mud are also a hazard. A means of handling this mixture may need to be provided, depending on the circumstances.
5. Keep all personnel not directly involved in the mixing operation away from the area unless they observe minimum safety requirements and have been apprised of the hazards involved.
-7-
ST054003I*
SAFE WORK PROCEDURE
Subject: Handling and Storing Asbestos Materials
Minimum Safety Equipment Requirements: 1. Side Shield Goggles must be worn. 2. Approved "Nose and Mouth" Dust Respirator must
be worn at all times. 3. A Safety Check List is to be filled out prior
to the job and properly approved.. Turn in to supervisor at completion of job.
Special Hazards: 1. Do not breathe asbestos dust. 2. Handle materials in such a manner as to minimize
exposure to dust. 3. Areas used to store asbestos containing materials
should be marked "Asbestos Material". Follow Safety Check List procedure when handling. 4. Destroy boxes that have contained asbestos materials as soon as boxes are empty. 5. Good housekeeping of shop areas is to be practiced. Clean up all loose dust on floor, machines, shelves, etc., by vacuuming. Wet down and dispose of dust while damp. Notify the Yard Department to dispose by landfill while material is still damp.
-8-
ST054Q035
SAFE- WORK PROCEDURE
' Subject: Sawing and Cutting by Hand
Minimum Safety Equipment Requirements: 1. Hard Hat must be worn. 2. Side Shield Goggles must be worn* 3. Approved "Nose and Mouth" Dust Respirator must
be worn at all times. 4. A Safety Check List is to be filled out prior
to the job and properly approved. Turn in to supervisor at completion of job. 5. All other safety equipment which is required by job location must be used. When in doubt, read Area Safe Work Procedures.
Special Hazards: 1. Do not breathe asbestos dust. 2. Wear the "Nose and Mouth" Dust Respirator when
removing asbestos material from package, installing, or cutting. 3. All people in the area other than those doing the work which are exposed to asbestos dust are required to observe .minimum safety requirements. 4. Special precautions shall be taken when using "Skil-Saw" for sawing asbestos materials to eliminate dust hazards and protect all people in the area.
-9-
ST0540036
%
1 1
PRE-JOB CHECK LIST
FOR HANDLING ASBESTOS MATERIALS
Job Description:
_______ _
Location:Maximum Service Temperature:
(Note: When under 1500 F., use non-asbestos material.)
YES NO
1. Area safe work procedure read and understood.
2. Safety Standard No.
apply?
3. Safe work permit required?
4. Handbook for Handling Asbestos Materials used?
5. Electrical clearance?
6. Red tags necessary?
7. Safe scaffolds in place?
8. Type of material to be removed known?
9. Disposal of used materials required?
10. Stencil on job denoting material used?
11. Signs up warning other personnel?
12. Has disposal of all debris been arranged?
13. Is water needed for controlling dust?
14. Have all involved personnel been instructed?
15. Safety Equipment required on job;
Chemical Goggles Face Shield Acid Hood Dust Respirator Gas Respirator Air Mask
Scott Air Pack Rubber Gloves
Rubber Boots Slicker Coat Slicker Pants
Safety Belt
Explosimeter Air Mover Exhaust Fan 32 Volt Transformer Other:
Cross out items not applicable.
Approvals:
Shop Superintendent Operations Superintendent Foreman_____________________ Date:________________________
- 11 -
ftEOO'lSOlS
THRESHOLD LIMIT VALUE We are required Co keep asbestos dust in the air within certain limits. These Threshold Limit Values are 2% fibers per cubic centimeter. In order to assure compliance with these limits, the Environ mental Health Group will make random samples. When field testing is necessary, call Environmental Health at 238-2121. In order to keep asbestos dust concentration within the proper limits, any dusty conditions connected with the handling of asbestos materials must be kept to an absolute minimum. This must be done as out lined in the previous Safe Work Procedures by wetting down the area, pre-soaking the material, or vacuuming the material as it is cut. Each individual job should be planned with this uppermost in mind.
i
- 12 -
ST054003?
E9820Q01S ;
c>
/
' HANDBOOK FOR
HANDLING ASBESTOS MATERIA L
-} THE DON CHEMICAL COMPANY
TEXAS DIVISION Maintenance Department
Supporting Services
July 1972 Rev
c
HANDBOOK FOR HANDLING ASBESTOS MATERIALS .Index
1. Purpose 2. Safety 3. Use of Handbook
Page fs)~ 2
.3 h
4. Safe V/ork Procedures
Fabrication of Asbestos Materials Mixing Cement Containing Asbestos
5
6
Handling and Storing Asbestos Materials
Sawing and Cutting by Hand
Insulation Removal .t
5. Insulator Safety Check List
6. Threshold Limit Value
7
.8 9
10 11.
ST0002864
- 1-
cc
'w./
PURPOSE
The purpose of this handbook is to define safe handling procedures for asbestos materials used in the Texas Division. The intent is to control the exposure of employees to asbestos dust through the proper use of safe work procedures and by the sub stitution of non-asbestos containing materials.
Asbestos is widely used as structural wall board, insulation, and roofing material. Asbestos fibers are used as a mechanical reinforcing matrix in. in sulation, roofing paper, certain piping systems, etc. However, Dow Engineering Specifications were revised to exclude asbestos-containing insulation prior to installation of Federal regulations controlling the use and handling of asbestos. Eventually, the use of asbestos will be eliminated as the ultimate solu tion to the problem.
The OSHA standards which, became, effective July 7, 1972, define the precautions required for asbestos handling and the allowable safe working limits.
Should a hazard exist, and these procedures appear insufficient, contact the superintendent of the Plant A or B Functional groups for exceptions or variations.
These procedures will be reissued prior to 7 December 72 to incorporate revisions dictated by results obtained from the Division Monitoring Program.
ST0002865
c
SAFETY
C
i. rr
r
The health of those who breathe asbestos dust may
be seriously affected. Results can be similar but
more serious than those caused by the more common
ly known materials such as silica and coal dust.
This phenomena has been observed for many centuries..
Current medical discoveries show that handling of
asbestos by a confirmed cigarette smoker is espec
ially hazardous in the area of potentially serious
lung disorders. It is recommended that those
persons handling asbestos not smoke cigarettes in
any quantity.
.--- **'
When working with materials which contain asbestos fiber, care must be taken to eliminate as much loose
dust as possible. Wetting, isolating the work area, or other suitable procedures to eliminate the dust
hazard are absolutely necessary. The main problem areas will be in removal of old, deteriorated in sulation and the sawing of Transite.
Respiratory protection, dust collectors, blowers, etc., will be mandatory where asbestos-containing materials must be handled.
The two "nose and mouth" dust respirators which have been approved by the Safety Department are: (1) MSA , * Dustfoe 77, Dow.Stock No. 15-26005, Cartridge Mo. * 15-23775, and (2) Wilson Dust Respirator, Dow Stock No, 15-25460, Cartridge No. 15-23790.
a
Disposal of asbestos will be in polyethylene bags, Dow Stock No. 15-05080 for large bag and 15-04170 through 15-04185 for small bags.
As required, special protective clothing such as cover alls, head covering and gloves will be provided. Such
requirements will be determined by the Division Moni toring Program.
Two lockers will be provided, so separated or isolated
as to prevent contamination of the employee1s street clothes from his work clothes.
Asbestos-contaminated clothing shall be placed in labeled, polyethylene bags for shipment to the laundry.
ST0002866
_
-3-
ST0002867
'C c USE OF HANDBOOK FOR HANDLING ASBESTOS MATERIALS
The Safe V/orlc Procedures outlined in this handbook are minimum requirements for working with asbestos containing materials. In some cases, job conditions may dictate more stringent requirements. These could Include com pletely wetting down the area with water when re moving old insulation, or completely isolating the work area with tarpaulins, etc. Specific require ments for each job will be detailed on the"Insulators Safety Check List." Because Dow's Engineering Specifications have .been re vised to exclude use of asbestos-containing insulation, most of the Safe V/orlc Procedures in this section of the Manual will seldom be referred to for new installations. Those procedures are to be used in conjunction vith Plant Safety Rules, Maintenance Standard Safe V/orlc Procedures for the Area, and Safety Standards.
-H-
ST0002868
SAFE WORK PROCEDURE
Subject: Shop Fabrication" With Asbestos Materials
Minimum Safety Equipment Requirements:
1. Side Shield Goggles must be worn.
2. Approved "Nose and Mouth" Dust Respirator must be worn at all times. (See Page 3)
3. There shall be a Dust Collecting System on Power Equipment adequate to remove large amounts of dust generated.
4. An Insulator Safety Checlc List is to be filled out prior to the job and properly approved. Turn in to supervisor at completion of job.
Special Precautions:
1. Do not breathe asbestos dust.
2. Do not opei'ate equipment if provision cannot be made to eliminate dust In a safe manner.
3. Normal precautions- must be taken for working with power equipment. (See specific Safe Work Procedure for Operating Power Driven Tools If in doubt).
4. When cleaning out the vacuum system of the machines, a respirator must be vjorn. Wet down dust prior to handling. Place the wet material in polyethylene bags, seal, label and notify Yard Department that asbestos waste is ready for proper disposal at landfill.
5. Good housekeeping in the shop area is to be practiced. Asbestos dust must be vacuumed throughout the shop area if and when such conditions exist.
6. Keep all personnel not directly involved in the fabrication * aeration away from the area unless they observe mir i safety requirements and have been apprised o; * hazards involved.
-5-
ST0002869
QSAFE WORK PROCEDURE
Subject: Mixing Material Vfhich Contains Asbestos
Minimum Safety Equipment Requirements:
1. Side Shield Goggles must be worn. 2. Approved "Nose and Mouth" Dust Respirator must
be worn at all times. (See Page 3J 3. An Insulator Safety Check List is to be filled
out prior to the job and properly approved. Turn in to supervisor at completion of Job.
Special Precautions: 1. Do not breathe asbestos dust. 2. When mixing whole sacks, do not open sacks and
dump into open mixing tray. Moisten asbestos by adding water through a small hole in sack until danger of dust is eliminated. Then the material can be removed if necessary to complete mixing operation to desired consistency. 3. Slipping or falling is a hazard to be considered when working around wet asbestos mud. 4. 'Back strains from handling containers of mixed mud are also a hazard. A means of handling this mixture may need to be provided, depending on the circumstances. 5. Keep all personnel not directly involved In the mixing operation away from the area unless they observe minimum safety requirements and have been apprised of the hazards involved. 6. All contaminated bags, boxes, waste, etc., shall be wetted, placed in labeled polyethylene bags and sent to landfill.
-6 -
ST0002870
(c
SAFE WORK PROCEDURE
II. l'
Subject: Handling and Storing Asbestos Materials
Minimum Safety Equipment Requirements:
1. Side Shield Goggles must be worn.
2. Approved "Nose and Mouth" Dust Respirator must be worn at all times. (See Page 3)
3. An Insulator Safety Check List is to be filled out prior to the job and properly approved. Turn in to supervisor at completion of job.
Special Precautions:
1. Do not breathe asbestos dust.
2. Handle materials in such a manner as to minimize . exposure to dust. Moisten material with water
spray before removing from container if material will not be damaged.
3. Areas used to store asbestos containing materials should be marked "Asbestos Material".
Jl. Cartons, boxes, etc., that have contained asbestos * materials should be wetted, broken and placed in labeled polyethylene bags for disposal.
5. Good housekeeping of shop areas is to be practiced. Clean up all loose dust on floor, machines, shelves, etc., by vacuuming. Wet down, place in labeled polyethylene bags and dispose of dust while damp. Notify the .gard-0opeptfiter.t to dispose by landfill while material is still damp. 0*/ss*os*/ 2V/7
-7
ST000287I
c
SAFE WORK PROCEDURE
Subject: Sawing and Cutting by Hand
Minimum Safety Equipment Requirements:
1. Hard Hat must be worn.
2. Side Shield Goggles must be worn.
3. Approved "Nose and Mouth" Dust Respirator must be worn at all times. (See Page 3)
4. An Insulator Safety Check List is to be filled out prior to the job and properly approved. Turn in to supervisor at comp;Xletfifo*n<11<
5. All other safety equipment which is required by Job location must be used. (Read Area Safe Work Procedures.)
Special Precautions:
1. Do not breathe asbestos dust.
2. YJear the "Nose and Mouth" Dust Respirator when removing'asbestos material from package. Installing, 'or cutting,
3. Keep all personnel not directly Involved in the operation away from the area unless they observe minimum safety requirements and have been apprised of the hazards involved.
4. Special precautions shall be taken when using "Skil-Savi" for sawing asbestos materials. To eliminate dust hazards and protect all people in the area, an air operated saw shall be used and the material shall be flooded with water.
5. If water will damage the material, a hand saw shall be used and sawdust collected with a portable vacuum whenever possible. If site work prohibits use of a vacuum pick-up, cuts should be made directly over a collection box or polyethylene bag.
6. All contaminated bags, boxes, waste, etc. shall be wetted, placed In labeled polyethylene bags and sent to landfill.
-8
ST0002872
SAFE WORK PROCEDURE
Subject: Insulation Removal
Minimum Safety Equipment Requirements:
1. Hard Hat must be worn.
2. Side Shield Goggles must be worn.
3. Approved "Nose and Mouth" Dust Respirator must be worn at all times. (See Page 3)
4. An Insulator Safety Check List is to be filled
out prior to the Job and properly approved.
Turn in to supervisor at completion of job.
/ft*, ifA
(/ 8f
S'""*+*'* l
5. All other safety equipment which is required
by Job location must be used. (Read Area Safe ' Work Procedure.)
Special Precautions:
1. Do not breathe asbestos dust.
2. Hazards from asbestos dust that falls, blows or may be scattered throughout the area must be eliminated,
3. Keep all personnel not directly Involved in the
insulation removal operation away from the area unless they observe minimum safety requirements and have been apprised of the hazards involved.
4. Use water to wet down the Insulation before and during removal.
5. Seal all material in labeled polyethylene bags as
removed. re-ard~Depar-tmeni is to be notified for
disposal at landfill.
wa stc
vs* f
* ***)
9
JOb* DESCRIPTION: 'LOCAT"ION
' AREA
x^'' Safe Work Permit Received
2. Area Safe Work Procedure Knovrn
V V
YES NO f JI j
r_
| | ' |
3. Nearest Phono
4, Nearest Eycbath and Safety Shower
5. Job Site in Safe Condition
| l j' |
6. Is Pipe or Equipment Safe to Work On?
1 j: f -----
7. Are Corrosive Chemicals j Involved?
jj j
*a. Can lines or
p~'j ] i
r equipment be drained? 1--* `--1
Is Adjacent Piping and Equipment Safe
i |j [ *------ 1 *--*
9. Red Tags Needed?
| 'j ] )
10. Burn Hazards Present?
|-------j j i
11. Craftsmen Lined Up With Check List?
r--i i--. 1--' *--
Special Hazards
Special Safety Precautions
Checked and Approved By:
Supt. Foreman ta~*ileadcr diiTtcman
DATE:
, DATE
C
II. ASBESTOS WORK '
YES 1. Handbook for Handling |---- ,
Asbestos Materials Used?--`
2. Signs and/or Barricades^--^ Up to Warn Others ?
3. Has Disposal of Debris 1l Been Arranged ?
4. Is Water Needed to Control Dust ?
L--i
5. Stencil on Job to DenotE---l Materials Used ? -
6. Have all Involved
1j
Personnel Been Informed ?
III. Special Safety Equipment. Require
--Coveralls
__ Chemical Goggles
to
__ Face Shield __ Acid Hood
-- Air Mask __ Dust Respirator
--1 fE? F?
-- Rubber Gloves
qq
-- Rubber Boots
^
__ Slicker Coat
co
__ Slicker Pants
__ Safety Belt
__ Hearing Protection
__Other: Specify
IV. Personnel on Job (Name) Efcposur Tirae-Hr
1. .
2. 3. . 4.
5.
6.
. 10 -
C
9
C
THRESHOLD LIMIT VALUE
No employee shall be exposed at any time to air
borne concentrations of asbestos fibers in excess
of 10 fibers, longer than 5 micrometers, per cubic
centimeter of air. The eight hour time-weighted
average shall not exceed five (*>) fibers per cubic
centimeter.*
In order to assure compliance with these limits, the Environmental Health Group will make random samples. When special field testing is desired,. call Environmental Health at 238-ST2T7
f 2.$)
In order to keep asbestos dust concentration within the proper limits,, any dusty conditions connected
with the handling of asbestos materials must be kept' to an absolute minimum. This must be done as out lined in the previous Safe Work Procedures by wetting down the area, pre-soaking the material, or vacuuming the material as it is cut. Each individual job should be planned with this uppermost in mind.
/
i ST0002871)
* Effective 1 July 1976, this limited is reduced from five (5) to tvio (2) fibers per cubic centimeter.
- 11 -
ST0002875
C
Latest word on asbestos won't be the last
Scientific evidence against asbestos continues to accumulate, and OSUA's much-delayed exposure standard goes on bringing criticism from all concerned parties. Meanwhile, millions of workers remain exposed to asbestos dust in plants throughout the world.'
D Bad newt about asbestos continues to make headlines. In September, for instance, Joseph A. Califano, Secre tary of Health, Education, and Wel fare (HEW), drew attention to an alarming statistic in a new study by the National Cancer Institute (NCJ) and the National Institute of Environmen tal Health Sciences (NIEHS): An aston ishing 17% of all cancer deaths in the U.S. over the next few decades wilt be linked to some previous exposure to asbestos.
Speaking at the AFL-CIO National Conference on Occupational Safety and Health, Califano said that the NCt/NIEItS report definitely rejects the conventional estimate that I to 5% of all U.S. cancer incidence is related to occupational exposure to carcinogenic agents. Estimates of 20% to as high as 38% are not unreasonable, he added.
EXPOSURE that kills--The joint
study estimates that between 8 and 11 million U.S. workers have been exposed to asbestos since the beginning of World War II. Of these, about 4 million have been "heavily ex posed,"--i.e., worked directly with the material most of the time--and 4 to 7 million have received "peripheral" exposure--e.g., of the sort that a maintenance worker would get in a plant where asbestos was being installed.
The,NCl/NlEHS report assumes that 20 to 25% of those in the first group will die of lung cancer, 7 to 10% of pleural or peritoneal mesothelioma (a particularly lethal'cancer), and B to 0% of gastrointestinal cancer. Assum ing that the risk to the second group is 25% that of the first one, the report concludes that a total of 2.15 million workers will die over the next 30 to 35 years, or about G7,000 per year. This
Fiberglass insulation, an alternative to asbestos, is considered taler
represents a whopping 17% of all cancers detected annually in the UJL
The joint study's figures on expo sure for workers are taken from HEW estimates (the department believes that 1.5 to 2.5 million U.S. workers are still being exposed to asbestos), while the fatality percentages are borrowed directly from a World Health Organi sation (WHO) position paper issued in early 1977. This link with the WHO document is confirmed by Joseph Wagoner, special assistant for carcino genesis with the Occupational Safety and Health Administration (OSHA), who was a member of the group of health experts that authored the WHO study.
Meanwhile, a spokesman for NCI/N1EHS says that the joint report is basically an update of epidemiological data on asbestos, in the light of new information uncovered in the past year.
Whatever its origin, the NCt/stEHS work is attracting its share of criticism by way of an attack on Califano's recent statement. Some claim that the HEW secretary is unnecessarily alarm ing the public. Asbestos no longer causes widespread' sickness because working conditions have changed, they
"Y-
Dr. Irving J. SelikoiT, a well-known authority on asbestos, and director of Mt. Sinai Medical Center's Environ mental 1 lealth Laboratory (New York City), notes that "Califano's remarks are projections based on limited data, and probably represent an upper limit." But he warns that even if Cali fano's figures are off by a factor of two, the problem is enormous.
However, a spokesman for the American Cancer Soc. (acs). New York City, feels that the NCI/NIF.K3 report docs overstate the problem.
INDUSTRY RESPONSE--The Asbestos. Information Assn. (aIA), Arlington, Va., an organization of asbestos processors, says that the nci/niehs data are being analyzed by the group's scientific advisors, and that a statement will be issued when the study is complete. Meanwhile, an AIA press release calls the report "simply anoth er extrapolation in statistical terms from the same data which have been available to the international scientific community for some time."
Another AIA press release, issued in response to a Califano statement (made in April) regarding a large
76 UIUIIOL (KUIMtklNC NOV (MM.* *. It>l
UiaVrO'-x^H'ir.y
ST0002876
i
U.S. firms still use it, despite its checkered career
8-h, time-weighted batfis, with a 15min ceiling of 5 fibcrs/cm1. All limits
apply only to fibers longer than 5 pm.
The term "asbestos" comprises a group of impure magnesium
(NIOSK, which serves in an advisory
silicate minerals--e.g., chrysotilc, amosite--that occur in fibrous form. Reports of the toxic properties of asbestos date back to the 1920s in
capacity, has recommended a limit of 0.1 fiber/cm\)
the U.S. However, it wasn't until the war broke out, when millions of workers were employed in shipyards insulating warships, that mass
OSHA is currently evaluating the economic impact of the proposed stan
exposure to asbestos dust occurred in this country.
dard, which is bound to afifcct both
The material enjoyed wide popularity as an insulator in plants and
processing and use of the material.
buildings until 1970, when, in response to mounting evidence of its
Predictably, industry reponse to the-
toxic properties, manufacturers slopped producing insulation made of
idea has not been favorable. AIA calls
loosely bound asbestos fiber.
the 0.5-fiber/cml limit "not technical
The Asbestos Information Assn, says that the 3,000 asbestos
ly feasible," and recommends instead
products made today in the U.S. contain chemically and physically
the adoption of 2 fibers/cm* as a
bound fibers that do not flake off. Current end-use breakdown:
permanent standard--one that can be
asbestos cement products (pipe, sheets), 22.4%; roofing products,
realized at a reasonable cost for dust
34.9%; asbestos paper, 4.3%; flooring products, 15.6%; packing and
control.
gaskets, 2.8%; thermal and electrical insulation, 1.2%; friction
On the other side of the spectrum,
products (brake linings), 8.8%; coatings and compounds, 2.7%;
Roy Sieinfurth, the asbestos workers'
plastics, 3.0%; textiles, 1.0%; and miscellaneous, 3.3%.
spokesman, feels that the only accept
able level is no asbestos exposure at all.
The union official says that, even if the
outbreak of asbestos-related diseases leading maker of asbestos products): exposure level is reduced to 0.5
among World War II shipyard work "Clinical evidence shows that lung fibcr/cm1, a worker would breathe in
ers, explains that such a heavy expo cancer in asbestos workers is virtually 4 million fibers in an 8-h workday. He
sure to asbestos existed before medical limited to those who smoke cigarettes, estimates that as many as 50% of the
information revealed the dangers in and that for practical purposes, lung members of his organization will even
volved. Since then, millions of dollars cancer as an asbestos-related disease tually die of asbestos-related diseases.
have been spent in dust-control equip would not be a problem were it not for
In Europe, there is also a move to
ment by miners, millers, processors cigarette smokers."
rut down on the exposure levclt which
and manufacturers of asbestos.
AIA is currently on a vigorous has been 2 fibers/cm* in the past few
In addition, note other asbestos- campaign to persuade industry work years. Italy, which lacks asbestos
industry spokesmen, the type of prod ers to stop smoking.
deposits, is attempting to phase out the
ucts made in the past--e.g., asbestos
"There is no doubt that exposure material completely. Sweden moved to
thermal insulation--are no longer and cigarette smoking have a synergis a 1-fiber/cm* standard a year ago,
produced. They were phased out in tic effect," says an ACS spokesman, and U.K. authorities are clamoring for
the early 1970s, when the inherent "but since so many workers included a reduction of the present limit.
hazards became apparent (see box).
in past studies were smokers or ex
Critics who complain that the osha
Nevertheless, asbestos is still used as smokers, it's difficult to assess the risk proposal does not go far enough in
an insulator or fire retardant in more to non-smokers."
protecting workers also question why
than 3,000 products ranging from
The synergism is acknowledged in the standard should apply only to
water pipes to brake linings. And an the who document. "Doth cigarette fibers longer than 5 pm. Both SelikofT
estimated 500 million tons of the mate smoking and exposure to asbestos and Wagoner, for example, believe
rial arc stilt around in plants and independently cause lung cancer.' that the smaller fibers are even more
`Inings throughout the U.S., accord- However, when present together, they active in producing lung tumors. Aitti,
i. g to Roy Sieinfurth, administrator of an in a multiplicative fashion." The according to SelikofT, "For each fiber
the insulation health-hazards pro NCI/XIE1IS study agrees, and admits longer than 5 pm, there may be at
grams for the International Assn, of that it would be an error to attempt to many as 100 shorter ones."
Heat and Frost Insulators and 'Asbes blame each type of cancer mentioned OSHA's Health Standards Project
tos Workers (Washington). Workers in the report on an exclusive cause.
Officer William Warren says that the
still exposed to asbestos are not
a new standard;--The current 5-pm length was the most practical
adequately protected, charges SelikofT. flareup of the asbestos controversy is of alternative because detection equip
ciCAftr.TTE JXiK-- Industry spokes more than marginal interest to osiia, ment does not pick up anything small
men also point out that exposure to which has been trying to modify pres er. Warren notes that available moni
asbestos alone may not be enough to ent rules governing exposure to the toring units detect only "from a few
cause lung cancer--the disease most material (the agency is studying the percent to 50%" of the actual number
commonly associated with the breath NCl/MKHS report).
of fibers in a sample.
ing of asbestos fibers--and that the
For more than three years, OSIIA
I.VSUl.VnOS DANGER--Spot checks
connection between exposure and ciga has been pushing a proposal to reduce with a number of U.S. insulation
rette smoking has not been stressed the jiermissible level of airliorne fibers manufacturers turned up no one still
enough. Says John A. McKinney, in the workplace from a present value making the asbestos-containing ver
president of Johns-Manvilie Corp. (a of 2 fibers/cm* to 0.5 fibcr/cm1 on an sion. However, there are still tons of it
78 UllMICtL INGIVIUINC NutlAtfcLft 4. !.**
c~~1
installed in chemical plants all over the world. Since the asbestos is loosely bound, the rutting, handling and tear ing down of such insulation poses a health hazard.
"If the insulation is intact, there's no problem," says an engineer with Brit ain's ICI, Ltd., "Whenever mainte nance requires stripping down and removal, we replace with a substitute material." lie adds that the firm does not specify asbestos for any new plants.
"We stopped using asbestos for insulation about seven or eight years ago," claims the safety manager of a U.S. refinery. "Although it is cheaper and easier to apply, the health risks persuaded us to switch to fiberglass and calcium carbide." He further notes that although some asbestos is still used, it is of the bonded type, which does not present a potential dust
hazard. The indirect risks of asbestos insula
tion were highlighted in a recent study of maintenance workers at American Cyanamid's facility in Bound Brook, N.J. The survey, commissioned by the
C
International Chemical Workers April 1977, NIOSIt said: "Pibrous glass
Union (lewu), Washington, and car scctns to be considerably less hazard
ried out by the Mt. Sinai Medical ous than asbestos. . . and, until more
Center, identifies the risks faced by information is available, the recom
maintenance workers (other than insu mended standard can also be applied
lation installers) when working in the to other manmade mineral fibers."
vicinity of an insulation job.
The N'tOSH paper suggests a standard
According to Larry Ahern, director of 3 fibers/cm3 for fibers of less than
of health and safety for icwu, the 3.5-^m dia. Larger fibers are not
results show that 44% of all workers, thought to be respirable.
regardless of job function, had some
Ralph Zumwalde, an industrial
form of asbestos-related lung abnor hygienist at NIOSH, points out that
mality. One group of workers exposed most of the exposure to fiberglass
for less than one month experienced a involves fibers with diameters greater
significant increase in the incidence of than 3.5 Mm, even though some special
lung disease.
products contain thinner ones.
Worse, the researchers discovered
"Fiberglass is an irritant, and can
that many of the workers' relatives, cause skin irritation or upper respira
who had not been in direct contact tory irritation," says Dr. Donald J.
with the material, were affected. Billmaicr, assistant medical director of
"About 123 wives were sick," says Owcns-Corning Fiberglas Corp. (To
Stcinfurth.
ledo, Ohio, "but our studies show that
HOW ABOUT SUBSTITUTES?--Such there are no chronic adverse healAf)
popular asbestos replacements as fi effects from using the materiaL" *H
berglass, mineral wool and calcium
Calcium silicate is classified asG3
silicate may have health hazards of nuisance dust, not a fiber. The ostCD
their own, but these have yet to be standard is 15 particles/cm3 for tED
identified.
respirable fraction.
TO
In a criteria document issued in
Vincent CavascQD
-O
Gulf Coast buildup may ease olefin glut
Q A more hopeful outlook for ethyl ene derivatives is triggering major expansions in the Gulf Coast area, and these may help alleviate, at leasi local-
\ *he ethylene surplus that is predict ed" through the early 1980s (Chan. Eng., Mar. 27, p. 80).
Consider, for example, the current buildup at tiie Rapune, Tex., complex of the US! Div. of National Distillers and Chemical Corp. The company, which last year increased its iiighdensity polyethylene (iturF.) capacity to 500 million lb/yr, Iwosicd its lowdensity jnlycihylcne (LDP) capacity by 200 million lb/yr this spring. Another ethylene-consuming addition is under way--USI will rnmpletc early next year a vinyl acetate mono* mcr expansion.Thiswill raise monomer capacity from 375 million lb/yr u* COO million lb/yr. The three expan
sions will consume a total of just under 500 million lb/yr of ethylene.
Shell has marked the tenth anniver sary of its complex at Gcismar, La., by inaugurating ethylene oxide and ethyl ene glycol trains, now about G0% completed. About a year ago, the company began work to inc rease oxide production from 300 to 700 million lb/yr, and glycol output from 150 to 350 million lb/yr. "This expansion will be ready for startup in early 1979," says plant manager Fred Foster. The ethylene oxide boost will require 340 million ib/yr of ethylene raw material.
Shell will also add flexibility to the Gulf Coast ethylene distribution sys tem with a new 251 -mi ethylene pipe line that will run from Muni Belvicu (just east of Houston) to Nnpoleonville, l.a., near Shell's petrochemical
plant at Norco. The company is build ing a 1.5-billion-lb/yr ethylene plant there, which is expected to go onstream in 1981. Says A. R. Flora, Shell's olefins business manager, "The pipeline will help to eliminate spot shortages in Texas and l.ouisiana complexes, which are the heart of the petrochemical industry."
USI executives now speak more optimistically about the future of downstream products, and predict a belter supply/demand balance. .a,., cording to George Kappas, vice-presi dent of National Petrochemicals Cor? (jointly owned by National Distillers and Owens-Illinois), "OFF. is currently moving away from oversupply.
"At present," says Kappas, "there it a slight surplus of HOPE. However, producers are not building up yearend inventories, and demand is grow ing steadily. Consequently, in 1980 and 1981, supply and demand will be somewhat tighter than they are today." Kappas notes that domestic need for the resin lias grown at an average annual rate nf more than 11% since 1971. LUF will he* in balance by 1980, according to USI estimates.
80
cmMic.iL lm;is> i wnu miv msi t. itn
./ * * .
V. /
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GUIDELINES FOR HANDLING OF SILICA DUST
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INTRODUCTION
These guidelines are provided to further alert our customers to the potentially harmful health effects and the increase of risk of serious disease caused by the inhalation of silica dust. The developing medical and scientific evidence strongly suggests that as the amount and/or duration of silica dust inhalation increases, the risk of serious and possibly fatal respiratory and other diseases also increases. Even a minimal inhalation of silica dust may pose a health hazard. While C-E is not in a position to agree or disagree with all the various scientific and medical studies, C-E does believe that various precautions could minimize whatever risk is associated with silica dust inhalation. These guidelines also provide information which may assist you in inplementing, monitoring and evaluating your own industrial hygiene and dust control programs to minimize potentially harmful personnel exposures. White C-E cannot assure that these procedures will eliminate risk, they should tend to reduce the risk.
CLASSIFICATION OF SILICA OUST
Free silica is uncombined silicon dioxide (SiOjL Silicates contain silicon and oxygen combined with other elements in a more com plex molecule. With the exception of asbestos and some talcs, silicate dusts should not ordinarily cause disabling lung conditions such as is produced by free silica.
It is uncombined or free silica that is most important in industrial dust exposure. So that an exposure can be properly evaluated, the percentage of uncombmed silica must be determined by petrographic analysis, preferably by x-ray diffraction or infra-red tech niques.
HARMFUL EFFECTS OF DUST It has been generally stated that the size of the offending dust particles is of extreme importance in determining the concentration of particles that may be suspended in the air. The size of particles also determines the depth to which these particles penetrate into the ing along with the quantity that may become deposited and retained. The particulates less than 10 microns in size are potentially the most harmful. Generally, when airborne particles are substantially larger than 10 microns in diameter, they are not of great concern because they are unable to penetrate into the lung where they could be damaging. Instead, they are removed, and collected, by the nasal passages or upper respiratory system. Also, it has been generally stated that the duration of dust inhalation is of extreme importance. Persons who for many years have continuously inhaled Irce silica dust have a great likelihood of contracting a silica related or caused disease. Those who only inter mittently inhale the dust have less risk of injury. In addition, those persons who smoke will increase the risk which otherwise exists.
INSTALLATION ANO TEAR-OUT
It is imooctant to be aware that exposure to silica dust can occur during installation of products that contain free silica as well at during tear-out and repair of facilities where products containing free silica have previously been installed.
Protective measures should be taken during both installation and tear-out and repair operations.
SILICOSIS Inhalation of progicssivcly excessive amounts of silica dust can produce rapidly-developing (acute) or chronic silicosis -- a disabling lung disease. Typically, the lung tissue reacts to the presence of silica panicles by forming fibrous matter around the particle. Evidence suggests that panicles below one micron (one-millionth of a meter) in size may be the most dangerous since they may penetrate deeper into the lungs in high concentrations, in rapidly-developing silicosis, symptoms appear 8 to 18 months after the fitsi exposure. Chronic silicosis, the type usually encountered in industry, generally is produced 5-20 years after tha chronic silica inhalation. Silicosis is generally classified in three separate stages by medical authorities.
The first stage of the disease produces no disability. The affected man can carry on his work as welt as ever. Frequently, the in dividual is not aware that anything is wrong, and the disease is rcvealetf only by opaque nodular shadows on a chest x-ray coupled witn a known exposure to crystalline free silica.
In the second stage, respiration may be affected in some persons but not in all by any meant. Laboied breathing, on heavy exertion usually is noted first, and a dry cough also may be present.
The third stage can develop after the second stage even though the individual hat been removed from exposure to silica dust. How;r. the progress of the disease will be slower without continued dust expoture. Breathing may become severely labored. The worker to below normal physically ataf it susceptible to retpiratoiy diseases. Chest x-ray may show an enlarged heart as a result o< the body s attempts to ovcrro.~'.e tin* ictuiance ol restricted blood vessels in the lungs. Pulmonary tuberculosis and emphysema are frequent complications.
to causing silicosis, the inhalation of silica dust can othr-wise weaken the lungs and their natural cleansing procf.l. As a result, the inhalation of silica dust may LJ contribution factor leading to other reipir.y'" v diseases. Medical and scientific analysis is continuing, ind the total effect of silica i\ ation is not known. What is known strong!^ Jicatcs that silica inhalation is hazardous to health.
THRESHOLD LIMIT VALUE CTLV)
TLV'S or Threshold Limit Values of mineral dusts are time weighted average concentrations considered permitsable for exposures of eight hours per day, five days per week that are published by the American Conference of Governmental Industrial Hygienists (ACGIH) and have been promulgated as standards of OSHA.
These values have been obtained from the experience of many groups in industry and from laboratory studies on animals. They are reviewed annually and changed as necessary on the basis of experience. Copies of TLV's may be obtained by writing to:
American Conference of Industrial Governmental Hygienist* U.S. Public Health Service P.O. Box 1937 Cincinnati, OH 45201
For maximum safety, C*E does not recommend the inhalation of any silica dust.
MEDICAL REQUIREMENTS An effective medical control program for exposed personnel will help prevent occupational diseases. Such a program can also serve as a check on engineering controls because symptoms of exposure in a group of workers could indicate inadequate controls. Examinations should be performed by, or under the supervision of a licensed physician and should be given to ail personnel prior to their atsignments to areas in which airborne concentrations oi dust may exceed the permissabie exposure limits. These examinations should include as a minimum the following:
1. Medical and occupational history 2. Chest x-ray 3. Pulmonary function studies 4. Physical including body weight, height and age
INDUSTRIAL HYGIENE MEASUREMENTS
Personnel dust exposures should be evaluated by dust measurements and a step-by-step analysis should be made to determine the conditions under which personnel are exposed to silica material. A standard procedure using personal sampling pumps should be employed in silica dust sampling. Sampling Data Sheet rrS315 found in the "NIOSH* Manual of Sampling Datasheets" may be used to sample respirable silica dust.
ABATEMENT OF PERSONNEL EXPOSURES
VENTILATION The primary means of controlling airborne dust is through use of proper ventilation. For detailed information refer to the ACGIH publication, "Industrial Ventilation, a Manual of Recommended Practices".
PROTECTIVE EQUIPMENT
Respiratory protection should be used by personnel working in dust environments where the ventilation system is inadequate or non-operational. A combination of both proper ventilation and respiratory protection would tend to eliminate most risks.
For details on use of respirators refer to the ANSI standard, ZS8.2-1969 "Practices for Respiratory Protection".
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National Institute lor Occupational Safety and Health U.S. Dapt. ol Health, Education and Welfare
c <rASBESTOS WORK INSULATOR CHECK LIST
it
JOB DESCRIPTION: ___ ___________________________ LOCATION: ______________________________________
!. AREA
YES MO
1. Safe Work Permit Received
t---------1 i-- j| 1
2. Area Save Work Procedure Known
i-------- 1' j--
\J |
3. Nearest Phone _
4. Nearest Eyebath and Safety Shower;
5. `Job Site in Safe Condition
i--------- 1 j--
6. Is Pipe or Equipment Safe to Work On?
7. Are Corrosive Chemicals Involved?
a. Can lines or equip ment be drained?
8. Is Adjacent Piping and Equipment Safe?
9. Red Tags Needed?
10. Burn Hazard Present?
11. Craftsmen Lined Up With . Check List?
SPECIAL HAZAROS
SPECIAL SAFETY PRECAUTIONS
II. ASBESTOS WORK
YES HO
1. Handbook for Handling i-
Asbestos Materials Used [
m
2. Type of Material to be r
Removed Known
[
in
3. Signs and/or Barricades r
Up to Warn Others
[
n
4. Has Disposal of Debris r
Been Arranged
[
in
5. Is Water Needed to Control Dust
j
| in
6. Stencil on Job to
Denote Materials Used |
]
7. Have All Involved
j
Personnel Been Informed]
in
8. Other ______________________
Special Safety Equipment
1. Chemical Goggles
2. Face Shield
-
3. Acid Hood
4. Air Mask
5. Dust Respirator
6. Rubber Gloves
7. Rubber Boots
8. Slicker Coat
9. Slicker Pants
10. Safety Belt
11. Hearing Protection
12. Other. Specify __
-- o o
q
(no OO CO
ISSUED BY: Supt. _____ Foreman __ Crewleader Craftsman
Date:
vgm:3-19-81
ST0000707
c
PIPE COVERER'S HANDBOOK
AND
FIELD NOTES
DEVELOPED BY
ROY J. ANDERSON Functional Polymers Maintenance
c
Reviewed BY
Piping Technology Sub-Center Maintenance Technology Center
Chairman - T. Madden
Printed and Distributed
by
Trades Training Department
1971
TABLE OF COfl IE NTS
ST0000708
SECTION I - GENERAL
Health and Safety ....................................................................... 1 General Theory and Practice .................................................. 4 Auto-Ignition .............................................................................. 9 Stress Corrosion Cracking ..................................................... 12
SECTION II - SELECTION GUIDELINES
Insulation Requirements ........................................................... 14 Selection Chart ......................................................................... 16 Thickness Tables
Careytemp ....................................................................... 17
Fiberglas ......................................................................... 20
Cellular Glass .......................................
23
Miscellaneous..................................................................... 24
Styrofoam ........................................................................... 25
Thurane ................................................................................ 26
SECTION III - MATERIALS
Careytemp ....................................................................
27
Flexible Tubing ........................................................................... 29
Mineral Wove Blankets ............................................................... 31
Fiberglas Blankets ..................................................................... 33
Fiberglas Pipe Insulation .................................................... 34
Foamglas .......................................................................................... 36
Ceramic Foam .................................................................................. 37
Low Temperature Insulation ..................................................... 38
Insulation Sundries ................................................................... 46
Jacketing ........................................................................................ 57
ST0Q00709
SECTION IV - PIPING APPLICATIONS
Dimensional Standards ......................................................... Single Layer Rigid ............................................................. Double Layer Rigid ............................................................. Fittings and Valves ............................................................. Fiberglas ................................................................................ Traced Systems .......................................................... Expansion Joints ................................................................. Styrofoam .................................................................................. Foamglas .................................................................................... Jacketing ................................................................................
66 68 69 70 83 84 88 93 ,99 102
SECTION V - EQUIPMENT APPLICATIONS
Careytemp Block and Segments ........................................ Preformed Pump Covers ...................................................... Block Vessel Insulation .................................................. Blanket Vessel Insulation ................................................ Contraction and Exoansion Joirts .................................. Reflective Insulation ....................................................... Styrofoam Vessel Insulation .......................................... Ethafoam Vessel Insulation .............................................. Banding and Supports ........................................................... Flashing Details ................................................................... Tables ......................................................................................
108 Ill 113 119 125 135 137 143 145 150 155
INTRODUCTION
ST 00007 10
While the principal use of this handbook will be as a source of reference information, a section has been added which covers a number of subjects related to the covering trade. For example, due to the fact that asbestos is known to be a health hazard, this subject is discussed by a member of the Dow Medical Staff. In this way, we hope you will understand why Dow has chosen to do away with asbestos containing insulating materials whenever possible.
Other subjects, such as heat transfer and "k" factors, are explained so that you may have a better basic understanding of terms and nomenclature. Older craftsmen will at some time have used most of the materials and methods listed in the book. There are some new techniques and materials listed, however, and these should be used to good advantage. Pre-cut head blocks and vinylacrylic mastics are good examples.
A large number of the sketches and tables have been taken from the Dow Engineering Practices. The help and cooperation of the Engineering Technical Specialists group has been greatly appreciated. A special "Thank You" is also due to the many other people who have helped with the compilation of this handbook.
Roy Anderson July, 1971
ST0Q007 I lpage 1
HEALTH AND SAFETY
Only in recent years have we become fully aware of the health hazards involved in working with asbestos-containing materials. In 1969 the Environmental Research Laboratory made a thorough study of air borne dust with relation to our coverers. As a result of this study and with strong support from the Medical Department, a program was initiated whereby we would (1) reduce drastically the purchase of all asbestoscontaining insulating materials, and (2) wear approved respiratory pro tection when working with asbestos. Since then the purchase of asbestoscontaining materials has been reduced to almost zero, and our Medical Department has instituted a very rigorous program of surveillance. See Medical Information on page 3.
In general, our dust problem can be divided into two categories, namely asbestos dust and nuisance dust. We have thousands of feet of lines still covered with asbestos insulation. These lines are continually being un covered and recovered. It is mandatory that respiratory protection be worn when these operations are taking place. Whenever possible the materials should be wetted down to reduce the dust. Nuisance dusts, while not as potentially dangerous as asbestos, can still be a very real source of irritation and respiratory protection is highly recommended. Rarely is a demolition job accomplished without a lot of dust. Wear your respirator.
Good housekeeping is essential in reducing the dust level in a working area. Always pick up torn off insulation and deposit in a dempster promptly. Do not cut insulation or mix up cement in a confined area and wear clean, loose-fitting clothing,
Two types of U. S. Bureau of Mines approved respirators are carried in stock. They are Dustfoe #66 tmeHES-?, ami Sure-Guard #R2090.* These pieces of equipment, properly fitted and kept in good condition. Will afford
srrrd 3 Ht A^foo&L, 7SO
STO0GO712
page
adequate protection. It is very important that the outer edges of the face piece form a perfect seal with the face. This should be checked frequently.
Coverers are frequently called upon to work on hot vessels and lines and to remove insulation that has been saturated with chemicals. This calls for alertness and caution. In other respects the safety habits of coverers should be no different than any other maintenance personnel. Remember, "Safety minjt-i>e-a'first consideration-and basic responsibility of.a.vamr-<Midlftftd-Division. employee. "
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ST00007I3 page J>
MEDICAL INFORMATION
The Medical Department is concerned about the hazards of excessive asbestos exposure not only because of the possibility of developing asbestosis, a permanent scarring condition of the lungs, but also because of the increased risk of developing lung cancer. We know that cigarette smoking along with exposure to asbestos dusts increases the risk of developing lung cancer about 80 times. Therefore, it is against your best general interest to smoke from a health standpoint-more so, if you are a pipe coverer.
Always wear the proper protective equipment when working with asbestos containing insulation materials.
The Medical Department maintains surveillance of all pipe coverers through periodic chest x-rays, measurements of breathing ability and health screening examinations. After an initial series of chest x-rays are taken, if you are under 40 years of age or have been pipe covering less than 10 years, follow up x-rays will be taken every year. If you are over 40 years of age or have been pipe covering more than 10 years, follow up chest x-rays will be taken every 6 months.
In recent years we have markedly reduced the use of asbestos in the Midland Plant. Our long range plans call for complete elimination of asbestos; however, until this is possible through the substitution of other materials, you are urged to use extreme caution when working with asbestos containing insulation.
Should you have any question relating to your health in regard to the handling of these materials, please contact the Medical Department at 6-2243.
ST0000714
p?/$e 4
GENERAL THEORY AND PRACTICE
Heat Transfer
The function of thermal insulation is to retard heat flow. We can best accomplish this by knowing how heat is transferred. Heat has two methods of transfer, namely, conduction and radiation. Convection, in the strict sense of the word, is not a method of heat transfer even though it is commonly used as such. Definitions are as follows:
Conduction is energy (heat) transferred from one body to another through actual physical contact. Example: heat traveling through a metal wire.
Radiation is energy (heat) transmitted through space from a hotter to a colder body. Example: the sun's heat on the earth.
Convection is the movement of a mass (air) from one location to another. Example: the movement of air from one part of a room to another.
One of the important measurements of an insulation's value is its thermal conductivity or "k" factor. This is defined as the amount of heat in Btu which will travel through a square foot of insulation one inch thick in one hour. The lower the "k" factor the better the insula tion. Another way of saying the same thing would be to state that a good insulating material is a poor heat conductor. One of the big reasons for this is that insulating materials contain a large number of air spaces, and dry, immobile air is a very poor conductor.
ST00007 15
page 5
The loss of heat due to radiation is countered by the use of reflective insulation. The use of aluminum foil over a steam traced line is a good example of this type of insulation. Reflective insulation is often used as a part of building construction. More recently we have seen "space age" reflective blankets and the gear worn by our astronauts.
Next, let us consider convection. Convection of air or heat energy within or around an insulation mass reduces its effectiveness. This is why an insulation made up of many tiny air cells is better than one containing larger air spaces. Convection currents, as we can call them, are set in motion by temperature differences. For example, we know that warm air moves upward.
In moving through an insulating material, heat will use all three modes of transfer. It is impossible to determine exactly the effect from each method. Therefore, the total amount is stated to be by conduction. Figure 1- 1 illustrates how heat energy moves through an insulation mass.
As a basis for comparison the following table shows the thermal conductivity (k factor) for a number of insulating materials.
Thermal Conductivity (k factor) Table
Material
Polyurethane Styrofoam Fiberglas Kaylo Careytemp Unibestos Foamglas
k factor at temperatures indicated
100F. 200F. 300F. 500F.
. 16 . 27 .27 .29 .36 . 34 . 36 . 42 . 50 . 32 . 37 . 42 . 51 .32 . 36 . 42 .50 . 42 . 48 . 56 . 73
1000F.
>' * .83 . 75
ST0000716
page 6
Figure 1-1
ST00007 I Jase 7
Insulation Usage
Insulation is used in our plant for several reasons. It may be used to conserve heat, control process temperatures, reduce noise levels, or serve as personnel protection. In the case of heat conservation, we make every effort to use insulation in thicknesses that will give a return in steam savings greater than the insulation cost. Depending upon the cost of installed insulation and the cost of steam, a definite thickness of insulation provides the lowest total cost.
Using bulk insulation to dampen noise is a separate field completely foreign to heat conservation. For this reason, the type and kind used on any particular job should be done only upon the recommendation of a specialist in that field.
Personnel protection generally refers to an installation of minimum thickness insulation where we are primarily concerned with keeping people from touching hot pipes or equipment. A good example would be on condensate run down lines. There is another area where we must be concerned with personnel protection and that is in the kind of jacketing used on fairly high surface temperatures. A metal jacket, because of its high thermal conductivity, is much more apt to cause a burn than asbestos paper even though they both have been used at the same temper ature.
ST00OO718
page 8
Weather and Vapor Barriers
The insulating material itself is only a part of the total system. Weather and vapor barriers also play a very important role. Weather barriers and covers are materials which will resist the elements and stand a certain amount of physical abuse. Thermal insulation depends upon finely divided air spaces to retard the flow of heat. When insulation becomes wet, all or part of the spaces become saturated with water. The transmission of heat through water is 27 times greater than through air. Besides lowering the effectiveness of the insulation, an additional heat loss occurs in drying out wet insulation.
Vapor barriers are materials which resist the passage of moisture in the vapor state. They are especially important on systems operating below normal (ambient) temperatures where the vapor pressure is lower than that on the outside. Under these conditions, vapor tends to force itself into the insulation. Then, as it encounters lower temperatures, it will reach the dew point and form water or frost as the case may be. Various types of resins have been formulated for use as vapor barriers. Some of these are Vinyl Chlorides, Hypolon, Monolar, and Acrylics.
ST000071 9 pap;e o
AUTO-IGNITIC'I
1.0 Description o Auto-Ignition
All combustible materials in the presence of air will ignite by themselves when heated above a temperature known as the auto-ignition temperature. This temperature as measured in standard tests is included in most tables of the fire and explosion properties of combustible. The "standard" auto-ignition temperatures for combustibles commonly handled in Dow plants range from about 500 to 1200F. It should be ohviou3 that as the temperature for handling a combustible fluid exceeds its auto ignition temperature, the design and operational requirements for acceptable fire and explosion prevention and control become more stringent.
2.0 Lowering of Auto-Ignition Temperatures by Insulations
2.1 Certain insulations can drastically lower the auto-ignition temperatures of combustible fluids frocuthe values given in fire property tables. For example, Doutherii^ A which has leaked or spilled into calcium silicate insulation has auto-ignited at temperatures of about 50GP F although the "standard" value for Dowtherm A is 1150F. Stearic acid, which has a standard auto ignition temperature of 743F, has auto-ignited at about 400F. when absorbed in calcium silicate insulation.
2.2 The exact mechanism for the lowering of auto-ignition temperatures by certain Insulations is not known. Retention by the insulation of heat from oxidation of the combustible fluid is probably an important factor. Typically, the insulation will be smoking, and when uncovered, will be found to be glowing. Occasionally, Che combustible vapors will burst into flame when Che insulation is uncovered.
3.0 Conditions Under Which the Auto-Ignition Temperature is Lowered
3.1 Auto-ignition temperature lowering by insulation has been observed in the plant and (or) the laboratory with chlorophcnetole, styrene (monomer or polymer), Dowtherm A, heat transfer oils, several lub oils, lanol, Acrowax, paraffin wax, stearic acid, polyglycols, VCN and ethylene oxide. It probabJv car. orevr with cry combustible fluid.
3.2 It has occurred when a liquid combustible has been absorbed into the insulation as a result of a leak or a spill. Absorption and wicking into the insulation appears necessary for the phenomenon. Significant auto-ignition temperature lowering has been observed with calcium silicate, magnesia, and asbestos-type insulations and with mineral wool cement. The effect has not been observed in either laboratory tests or in the field with glass foam and Dot? ceramic foam insulations.
ST 00 00720
page 10
3.2 (Cont'd.)
These insulations are closed cell and almost completely nonabsorptive. Glass fiber Insulation has not shown the effect in laboratory tests nor in the plant, but is not suitable for use at temperatures where auto-ignition has been a problem. "Kaylo", "Unibest03" and "Thermbestos" can cause marked lowering of auto ignition temperatures. A3 manufactured "Careytemp 1500" has only a slight tendency to lower autoignition temoeraturcc and is much less absorptive and shows much less wieking action than "Kaylo". However, it contains temporary binders which degrade rapidly, often with evolution of much smoke, at temperatures above 400 F. After decomposition of these binders, its absorption, wicking and autoignition behavior approaches that of "Kaylo".
3.3 The principle points of trouble have been around leaky valve packing glands, thermocouple connections, equipment flanges and places where Insulation contacts horizontal flat surfaces such as floor plates. Leakage collects on the flat surface and is absorbed into the insulation by wicking action.
4.0 Corrective Measures
4.1 Use an insulation that has little or no tendency to lower auto-ignition temperatures.
4.1.1 Where the operating temperature, proximity to potential 'leak sources and consequences of an auto-lgnitlon are critical, "Foanglas" is the recommended insulation. (Note: Dow ceramic foam is similar to "Foamglas" in respect to auto-ignition effect and compressive strength, has a higher effective service temperature, but is not yet available in quantity.)
4.2 Auto-Ignition can be eliminated in thermal insulation if means are used to prevent oils or organic fluids from being absorbed into the insulation. These corrective steps should be considered for new construction as well as for correcting existing conditions. They may be used separately or in combination to suit each specific case.
4.2.1 Eliminate the source of leakage. This may mean repacking valve stems, replacing leaky gaskets, seal welding screwed joints, etc.
ST000072I
page 11
4.2.2 Omit che insulation 6 or 8 inches each side of Che leak. If necessary, provide personnel protection by means of a guard or expanded metal grille. Finish edges of insulation thus exposed with a beveled fillet of B & W K-20 cement. Due consid eration should be given to increase heat loss and possible thermal shock (on outdoor installations) in using this method.
'
4.2.3 Install all valves, for the particular service, with stems in horizontal position so that any leaks will drip away from the insulation.
4.2.4 Provide sheet metal trough to carry leakage away from insulation below.
4.2.5 Cover insulation, in area of potential leak, with a hydraulic setting, oil resistant cement such as Babcock and Wilcox K-20 cement.
4.2.6 Consider use of an all metallic reflective type insulation.
4.2.7 Provide for adequate inspection and repair of equip ment and piping systems to prevent leaks. Remove or replace insulation found to be oil soaked.
4.2.8 Note: See special application (Auto-Ignition) of aluminum foil on vertical vessels 43" O.D. and larger. See M8-515.
ST0000722
pap;e 12
STRESS CORROSION CRACKING OF 200 SERIES STAINLESS STEEL
1.0 All 300 Series Stainless Steels are subject to stress corrosion cracking caused by Chloride attack under suitable conditions of moisture, temperature and metal stress. The 400 Series Stainless Steels are immune from this phenomenon.
1.1 The main source of Chlorides is from industrial or marine atmospheres which induce chloride contamination of the metal surface.
1.2 All commercially available inorganic insulation contains sufficient leachable chlorides in trace quantities to cause cracking.
Some Chemical Plant atmospheres are heavily chloridecontaminated. Chlorides from external sources often enter the system through condensation, rainfall, leaky valves, packing glands, etc., wetting the insulation by penetration through breaks or cracks in the insulation, and concentrating to a level where external stress cor rosion takes place.
1.3 Provide and install expansion joints as required in in sulation and weatherproofing which will prevent moisture from getting into the Insulation causing stress corrosion.
1.4 The most effective preventative would be to take great care to see that the insulation, piping and equipment is dry at the time of application and kept dry. Weather proof as follows: Vapor seal mastic, weatherproof felt or metal jacket. See M8-481 and M8-555. Chloride leaching cannot take place without moisture. Failures of 300 Series Stainless Steels are most common at 150F thru 400F.
1.5 Purchase only inhibited insulations (1) Calcium Silicate, Thermasil - Baldwin Ehret Hill; (2) Kaylo and Fiberglas Owens-Corning? (3) Sodium Silicate; Unibestos-Pittsburgh Corning Corporation.
1.6 As an additional precaution in case moisture does get through the insulation, or where the stainless steel piping and equipment has become contaminated or was sub ject to a Chloride atmosphere in storage or erection, clean and coat before insulating.
1.7 Cleaning
a. Wash with condensate and a non-chloride detergent. Condensate shall be tested for chloride count.
b. Steam clean. c. S.S.P.C. No. 6 Commercial Blast Cleaning.
STQfliW^23
1.8 Apply coatings IMMEDIATELY after cleaning.
a. Silicone coating - for temperature up thru 1000F maximum, SOO^F continuous.
1. .Dampney Company Thur-Ma-Lox #70 Doylestown, Pennsylvania
b. Silicone Coating - for temperature up to 1400F maximum.
Thur-Ma-Lox #240.
2.0 IMPORTANT:
2.1 DO NOT USE:
a. CHLORINATED ORGANIC COATINGS. b. CHLORIDE CONTAMINATED TESTING PROCEDURES.
#
C. WET MIXES OF INSULATING CEMENTS AGAINST THE STAINLESS STEEL SURFACES.
2.2 DO NOT HANDLE WITH SWEATY HANDS OR DIRTY GLOVES, AFTER CLEANING.
C
ST0000724
page 14
INSULATION REQUIREMENTS
The temperature of pipe or equipment on which insulation is installed is one of the prime considerations in the selection of an insulating material. Each type of insulation has a maximum and minimum service temperature; therefore, the proper type should be selected for the temperature service involved. See Table 2-1. No attempt has been made to go into detail on the Table itself and the materials listed are not all inclusive.
There are specific applications where the material listed for a certain temperature will not work nearly as well as another. Detailed information on each material listed in the Table can be found in the "Materials"' section. Details for the use of the materials can be found under either the "'Piping Applications" or"Equipment Applications" sections.
The next requisite is the form of insulation to be used. Some of the forms and their applications are listed below:
1. Rigid insulation for structural strength. Pipes, vessels, and uniformly shaped equipment subjected to mechanical abuse.
2. Semi-rigid or flexible insulation for use when external support is available and where shapes and contours make rigid insulation difficult and uneconomical to use.
3. Blanket insulation for ducts and when expansion and com pression are necessary. Blankets are frequently used between vessel walls and rigid insulation to provide a thermal and mechanical cushion.
ST0000725
page 15
4. Sprayed urethane foams for large surfaces subjected to only moderate temperatures.
5. Poured or loose insulation for filling cavities or tight enclosures.
The right thickness of the proper insulating material is probably the next most important criterion. See Tables 2-3 thru 2-11 for thicknesses.
Finally, the proper application of the right weather and/or vapor barrier is extremely important. Insulation systems must be kept dry. On below ambient temperature applications a vapor barrier is also necessary. Details on insulating cements, jacketing and mastics can be found in the "Materials" section.
ST 00 0 07 26
page 16
INSULATION SELECTION CHART
Temp. F. Service
Pipe
Standard
Alternate
Equipment
Standard
Alternate
1200 Hot
Careytemp
550 400# Steam
Careytemp
Foamglas
240 150
75
35 -100
10# Steam
Fiberglas, also on steam traced lines
Personnel Fiberglas protection
Condensa Fiberglas tion control
Chilled water
Styrofoam FB
Brines Refriger ants
Styrofoam FB
Careytemp
Careytemp
Ethafoam Armaflex Dow "FX" Foamglas
Urethane
Careytemp blocks; Mineral Wool
Insulating Cement blocks/metal
<3 /
mesh blankets
Fiberglas metal mesh blankets 2500 to 1000F. 48" dia. up
Above 250F. & 48" dia. up
Foamglas
Insulating Cement Careytemp on 18" or smaller heads
Fiberglas blanket Careytemp -
Fiberglas Sprayed Cork
E thafoam
Styrofoam FB or FR
Styrofoam FB or FR
Urethane Urethane
Table 2-1
ST0000727
page 17
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page 18
CAREYTEMP 1500 THICKNESS TABLE 10 YR. DEPRECIATION (SHORT TERM)
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ST0000729
page 19
CAREtfTEMP 1500 THICKNESS TABLE 20 YR. DEPRECIATION (LONG TERM )
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ST000073 I
page 21
n B f? G L A S /fJSULA T /O N rUICKHCSS TABLE.
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ST 0000732
page
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CELLULAR GLASS THICKNESS TABLES RECOMMENDED THICKNESS HI INCHES
page 23
Ambient Air at 90F30 j> Relative Humidity
Pipe
PIPE SURFACE TEMPERATURE (F .)
Size
(KPS) 45 30 15 0 -25 -50 -100 -200 -300
1/2 1.0 1.0 1.5 2.0 2.0 2.5 3.0 4.0 4.5 1 1.0 1.0 2.0 2.0 2.5 3.0 3.5 4.5 5.0
1 1/2 1.0 1.5 2.0 2.5 3.0 3.0 4.0 5.0 5.5j 2 1.0 1.5 2.0 2.5 3.0 3.0 4.0 5.0 6.0! 4 1.0 1.5 2.5 2.5 3.0 3.5 4.5 5.5 6.5 6 1.0 1.5 2.5 2.5 3.0 3.5 4.5 6.0 7.0 8 1.5 2.0 2.5 2.5 3.0 4.0 5-0 6.0 7.5
10 1.5 2.0 2.5 3-0 3-5 4.0 5.0 6.5 8.0 14 1.5 2.0 2.5 3.0 3.5 4.5 5.5 7.0 8.5 18 1.5 2.0 3.0 3.0 3.5 4.5 5.5 7.5 9.0 24 1.5! 2.0 3.0 3.0 3.5 5.0 6.0 8.0 '9/5 30 1.5 2.0 3-0 3.0 4.0 5.0 6.0 8.0; 10.0
Vessel Dia. _Eeet 45
VESSEL SURFACE TE14PERA3JURE (F.)
30 L5
0 -25 -50 -100 -200 -300
_3 1-5 2.0 3-0 3.5 4.0 5.0 6.0 8.5 10.5 6 1.5 2.5 3-0 3.5 4.5 5.0 6.5 9.0 11.0
10 1.5 2.5 3.0 3.5 4.5 5.5 6.5 9-5 11.5
Plat
1.5 2.5 3-0 3.5 4.5 5-5 7.0 10.0 12.0
Pipe or
V cbbcl
Size
1 1/2" or less
2" thru 3 1/2" 4" thru 6"
8 thru 10"
12 thru 30" 36 to 48"
48 to flat
PIPE SURFACE TEMPERATURE (F.)
To 300 301-400 4oi-500 50l-6oo` 601-700 '701-800
_JUQ____ ___ L.-Q
1.0 1.5 1.0 1.5
. 1.5 1.5 2.0
2.0 2.0 2.0 2.5 2.5 3.0
2.5 3.0 3.0
1.5 2.0 2.5 3.0 3.0 3.5 --1^ . , 2.0 2.5 3.0 3-5 4.0
1.5 2.0 2.5 3.0 3.5 ' 4.0
2.0 2.0 2.5 -JLiP- -JL3____ 4.0
Table 2-8
. ST0000734
page 2*J MISCELLANEOUS INSULATION THICKNESS TABLES
C
CO
oo
CO
Hor -t
TEMP. DEGREE
F.
ICO - 200 201- 300 301-400 401- 500 501- 600 601- 700
801 900 901 - 1000 1001 - 1100 1101 - 1200 1201- 1300 1301 - 1500 1501 - 1600 1601- 1800
EQUIPMENT INSULATION - INOOOR. (ADD 4 INCH FOR OUTDOOR)
FIBERGLAS BLANKET
MINERAL WOOL
BLANKET
MINERAL WOOL BLOCK
MINERAL WOOL CEMENT
1
.1 1
14
2
j 24
44 54
!
11
1
1 14 | 14
14 j 14 j 2
14 | 2
| 24
2 24 3
2 3 34 24 34 j 4
24 34 4
3 i 4 ! 44
3
j4
i 44
34 ! ~4 ! 5
i 44 j 5
>5
1 54
1 54 1 6
1 64
......................................... <
2. ' r\
e
ST0000735 pa^e 25
STYROFOAM THICKNESS TABLES
C FOR PIPE & VESSEL ITiSULATIOIi
RECOMMENDED THICKNESS IN INCHES USING STYROFOAM FB BRAND
Ambient Air at 90F
PIPE SIZE (NPS)
45 30
1/2 1.0 1.5
3/4 1.0 1.5
1 1.0 1.5
1-1/4 1.0 1.5
1-1/2 1.0 1.5
2 1.0 1.5
2-1/2 1.5 1.5
3 1.5 1.5
4 1.5 1.5
86 1.5 2.0 1.5 2.0
10 1.5 2.0
1814 1.5 2.0 1.5 2.0
24 1.5 2.0
30 1.5 2.0
85% Relative Humidity
Pipe Surface Temperature
15 0 -25
-75
o
tr> i
-100 -150
i
------- j
-200 -250 -300 | i
1.5 1.5 2.0 2.0 2.5 2.5 3.0 3.5 3.5 4.0
1.5 1.5 2.0 2.5 2.5 3.0 3.0 3.5 1.5 2.0 2.0 2.5 2.5 3.0 3.5 3.5
3.5 4.0 4.0 4.0
1.5 2.0 2.0 2.5 3.0 3.0 3.5 4.0 1.5 2.0 2.5 2.5 3.0 3.0 3.5 4.0 2.0 2.0 2.5 2.5 3.0 3.5 3.5 4.0 2.0 2.0 2.5 3.0 3.0 3.5 4.0 4.5 2.0 2.0 2.5 3.0 3.5 3.5 4.0 4.5 2.0 2.0 2.5 3.0 3.5 3.5 4.5 4.5 2.0 2.5 3.0 3.5 3.5 4.0 4.5 5.0
4*1
o | j
f* 1
2.0 2.5 3.0 3.5
5.0 5.5
2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5
2.0 2.5 3.0 3.5 j 4.0 4.5 5.0 6.0 .
2.5 2.5 3.0 3.5 4.0 4.5 5.5 6.0
2.5 2.5 3.5 4.C i4.5 5.0 5.5 6.0
2.5 j 2.5 3.5 4.0 j 4.5
6.0 6.5
4.0 4.5 4.0 4.5 4.5 4.5 4.5 5.0 5.0 5.0 5.0 5.5 5.5 6.-0 j
6.0 6_-j
6.0 6.5 J
6.5 7.0 j
6.5 7 Q~j t
7.0 7.5 ; 7.0 JJJ
RECOMMENDED THICKNESS IN INCHES USING STYROFOAM FR BRAND
Ambient Air at 90F
VESSEL
DIA.
45 30
(FEET)
Vesse 15
Surface Temperature (F)
--
1---------
0 -25 -50 -75 -100
85% Relative Humidity
r -150 -200 -250 -300
3 1.5 2.0 2.0 2.5 3.0 3.5 4.0 4.5 5.5 6.0 6.5 7.0
6 1.5 2.0 2.5 2.5 3.5 A .0 4.5 5.0 5.5 6.5 7.0 7.5
C 10 1.5 2.0 2.5 2.5 3.5 4.0 4.5 5.0 6.0 6.5 7.0 7.5
20 1.5 2.0 2.5 2.5 3.5 4.0 4.5 5.0 6.0 6.5 7.5 8.0
Flat 1.5 2.0 2.5 2.5 3.5 4.0 4.5 5.0 6.0 7.0 7.5 8.0-
Tahir- ?-m
.1* -
;ST0000736
inurane -hicknes:; FOP. PIPE
RECO?"'.ENDED TUICKENSS IN INCHES lsi::g :::lra.* e bra::e
page 26
Ambient Air at 90F
PIPE SIZE (KPS)
1/2
3/A
45 j 30
1.0 1.0 1.0 1.0
1 1.0 1.0
1-1/4 1.0 1.0
1-1/2 1.0 1.0
2 1.0 1.0
2-1/2 1.0 l.C
3 1.0 1.0
4 1.0 1.0
6 1.0 1.0
8 1.0 1.0
10 1.0 1.0
14 1.0 1.0
18 1.0 1.0
24' 1.0 1 1.0
30 1.0 1.0
35% Relative Humidity
Pipe Surface Tcr-nerat. ''r {' ") 15 0 -25 -50 1 -75 -lot1! -150 -200 -250 -300
1.0
1.0
1.5
1.3 iz.O
T t)
2.3
^ r\ 0 .V/
3.0
3.0
1.0 1.0 1.3 1.5 2.0 2.0 ?. . J 3.0 3.0 3.0
1.0 1.5 1.5 2.0 2.0 2 .b 3.0 3.0 3.5 3.5
1.0 1.5 1.5 2.0
2.5 !:.o 3.0 3.5 3.5
1.0 1.5 1.5 2.0 2.0 ?.5 3.0 3.5 3.5 3.5 1.0 1.5 1.5 2.0 |:.s > c 3.0 3.5 3.5 4.0
1.0 1.5 1.5 2.0 : .5 2.3 5.0 3.5 4.0 4.0
1.5 1.5 2.0 2.0 !..: 3.0 3.5 5.5 4.G 4.0
2.0 i:.G
1.5 1.5 2.0
3.0 3.5 4.0 4.0 4.5
1.5 1.5 2.0 2.5 j 2.5 3.0 4.0 A.O 4.5 4.5
1.5 1.5 2.0 2.5 '.n |
4.0 4.5 4.5 j; n
1.5
1.5
2.C
7
C
.
Z2.
3.0 i 5.5
4.0
4.5
5.0
5.0
1.5 1.5 2.0 |2.5 5.0 | 3.5 *.5 4.5 5.0 5.5 !
1.5 1.5 2.0 | 2.5 js.O ! 2.5 I 4.5 5.0 5.5 5.5 i 1.5 1.5 2.0 |2.5 :.r' 3.5 i 4.5 5.0 5.5 5.5 1.5 1.5 2.0 i2.5 5.0 ! j.rs A.5 5.0 5.5 6.0
Ambient Air at 90F
VESSEL DIA. .(FEET).,
.3 6
10
20
Flat
45
1.0 1.0 1.0 1.0 1.0
30
1.0 1.0 1.0 1.0 1.5
RECOMMENDED Ti'ICF.NESS IN INCHES USING 7FURANE NIANC
C5C Relative Humidity
VESSEL SURFACE TEMPERATURE (LF) 15 0 -25 -50 -75 -100 -150
-200 -250 -300
1.5 1.5 2.0 2.5 3.0 3.5 4.5 L 5 6.0 6.0 1.5 2.0 2.5 3.0 3.5 4.0 5.0 5.5 6.0 6.5 1.5 2.0 2.5 3.0 3.5 4.0 5.0 5.5 6.5 6.5 1.5 2.0 2.5 3.0 3.5 4.0 5.0 6.0 6.5 6.5 1.5 2.0 2.5 3.0 3.5 4.0 5.0 j 6.0 6.5 7.0
ST0000737
page 27
Qkv\v::r: : '^o *
1.0 Manufactured by Philip Carey Corp.
2.0 Physical Properties
/Z0 6
Temperature Limits........................................................................ Maximum 1<SOOF.
Continuous l'WQF. Cyclic 1500F.
Density (dry) ............................................. . ....................... 11-13 lhs./cu.ft.
Compressive Strength .................................................. 5% deformation 100 psi.
Linear Shrinkage (percent) 1200F. for 24 hours ......................................................................................
.60
1500F. for 24 hours........................................................
1.20
Water Absorption (percent)
By Volume Q 90% relative humidity 4 weeks..........................
1.30
By Volume, Immersed 24 hours.......................................................... . . 2.70
Acid Resistance (after 24 hour immersion)
25% Sulfuric or Hydrochloric Acid ........... Mo Effect
Thermal Conductivity (Expressed as BTU/hr. sq.ft. F./l" thickness)
300F. Mean.................................................................................................................... 42
500F. Mean...................................
.51
700F. Mean.................................................................................................................... 64
Made with expanded Perlite. Asbestos content 0.
3.0 Standard Sizes
Copper tubing - 3/4" O.D. through 3-1/S" O.D., half sections. Iron Pipe - 1/4" through 24" IPS, half sections. Thickness - 1" through 3", single layer. Segmental - 12-3/4" wide curved sections through 60" O.D. Block Insulation:
Standard widths - 6", 12" and 24" Standard lengths - IS" and 36" Standard thickness - 1" through 6", in 1/2" increments
4.0 Available Shapes
Block Pipe Premolded Elbows
Prejacketed (withAluminura) pipe insulation Traced pipe insulation
5.0 Application
5.1 Pipe Insulation - See page 68
5.2 Block and Segment Insulation - See Dage 108.
6.0 Reference pages 17 Recommended Thickness for Careytemp 1500
105 Wall and Floor Sleeve Sizes
106 Height of Pipe Insulations
* See next page
;ST0000738
pap;e 28
CAREYTEMP 1500
* The first time Careytexnp 1500 insulation is brought up to operating temperatures, some discoloration of the insulation occurs at the hot surface, with the possible accompaniment of a one time emission of slight organic odor and smoke. This is caused by the baking out of phenolic resin and starch binders that give the insulation added strength during the molding operation and in its subsequent transfer to the oven to initiate the drying and curing process. The in organic component of the binder system (bentonite clay) then takes over as the drying and curing proceeds, and becomes the primary binder of the product in its final finished form and provides the required strength to the product under full service conditions.
c
'X
ST0000739
page 29
FLEXIBLE TUBING INSULATION
1.0 Uses
For preventing condensation, sweating and drip on cold and chilled water pipes, tubing and equipment in air conditioning, cooling and refrigeration systems. Also suited for dual temperature and heated fluid lines at temperatures up to
220F.
2.0 Description
Flexible, expanded cellular synthetic elastomer with stabi lizing compounds added. Tubular and sheet form for thermal, insulation and condensation control.
Flexible, strong and touch at all working temperatures may be installed by slipping over pipe ends. Self-extin guishing resistant to ozone, mildew, oils and solvents.
3.0 Acceptable Manufacturer
3.1 Baldwin-Ehret-Hill - "Monoflex"
3.2 Johns Manville Co. - "Aerotype"
3.3 Armstrong Cork Co. - "Armaflex"
3.4 Owens Corning - "0-C Flexible Tubing"
4.0 Available Sizes
4.1 Tubing - to fit standard sizes up to and includincr 3
inch, in wall thickness 3/2", 1/2", 3/4". 6 ft. lenaths in all thicknesses.
4.2 Sheets - Width and Length: 24" x 60", 48" x 60" Thicknesses: 1/8" thru 1", by 1/8" increments
5.0 Technical Data: Thermal Conductivity K at
0.28
Temperature Range Density, Average Tensil Strength Water Vapor Permeability Self-estinguishing Standard Sizes
-20 to 220rtF 6.5 lb/cu. ft. 80 lb./sq. in. 0.12 perm-in. by ASTM D 1692 ;
;ST000074D
Recommended Thicknesses:
page 30
C
Conditions
Sizes
50F
Line Temperatures
32PF
0PF
Normal (85<>F & 70% R.H.)
3/8" O.D. 3" IPS
3/8" Nominal
1/2" Nominal
3/4" Nominal
3" 4" IPS
1/2" Nominal
1/2" Nominal
3/4" Sheet
Over 4" & Flat
3/8" Sheet
5/8" Sheet
1" Sheet
7.0 Application
7.1 On pipes or tubing install by one of the following methods.
7.11 Slipping over the ends of pipes.
7.12 Slitting tubing and applying it on connected piping.
7.13 Applying sheet material around pipes and fittings, holding it in place with adhesive and tapes.
7.2 In all applications, abutting cut surfaces of butted and longitudinal joints shall be brush-coated with adhesive before joining.
7.3 Fittings, valves, etc. shall have fabricated covers cut from specified thickness tubing or sheet and applied with adhesives.
8.0 Finishing
3.1 The surface may be coated with a vinyl lacquer which will flex after drying.
8.2 For use outdoors, weatherproof jackets of asphalt coated roofing, aluminum or galvanized sheet metal can be used.
MIMERAL
. ST000074I
Mi-TAL
&UsNKET-S
page 31
Gi
e
1.0. product:
5t.O. . Description:
SPUN WOOL BLANKET INSULATION (METAL MESH)
Spun Mineral Wool enclosed between facings of flexible, metal fabrics, held together by metal tie v/ircs.
Standard Types of Facings arr:<=
3.0. 4-.0
1. 1-inch wire mesh both sides 2. l-inch wire mesh and stucco lath
2A. 1-inch wire mesh and expanded metal lath
2B. 1-inch wire mesh 3/8" ribbed lath (rib turned in)
3. Stucco lath both sides
3A. Expanded metal lath both sides
3B. Stucco lath one side, expanded metal lath other side
4. Stucco lath and 3/8" ribbed lath (rib turned in)
4A. Stucco lath and 3/8" ribbed lath (rib turned out)
5. Stucco lath and 3/l" ribbed lath (rib turned in)
.5A. Stucco lath and 3/4" ribbed lath (rib turned out)
6 3/8" ribbed lath both sides
7. No. 12 mesh fly screen both sides
e. 3/8" ribbed lath (rib turned in) and 3/4" ribbed lath
Manufacturers 1 (rib turned out)
/Sait Laiest Bulletins}
B-E-H
Mctal-mcsh Blanket
11 thru I4A
OCF
Metal-mesh Blanket 0, R. H, L
JM Banroc Blanket ?102 thru M2A
Eagle Mineral Wool Blanket 1200 thru r208
48 Metal-mesh Blanket *4S00 thru -4S06
Uses:
For heated surfaces up to 1200F, in power plants, refineries and chemical plants. Used on tanks, towers, vessels, fan housings, turbines, ovens, breechings, boilers, etc.
F.o. Features:
Light-weight, made of Spun Mineral Wool. Factory-made to insure consistent quality. Stable, resistant to vibration. Flexible, easily applied to any regular-curved, or flat surface.
6.0 _T__e_c_h__n_i_c_a__l _D__a_t_a;
D&naiiy ;
Temperature Limit, maximum
1200 F
{With monel wire mesh,
Sizes
Length Width
up to
-
IDOO F)/"MA>0 LIMIT t/SAStr S 1400F
48, 96 inches
24 inches
Thicknesses
- 1 to 8" by 1/2" increments
1400 BLANKET: 1200 BLANKET: 1000 BLANKET:
Density: 10 lbs./cu.ft. Temperature Density: 8 lbs./cu.ft. Temperature Density: 6 lbs./cu.ft. Temperature
limit: 1400 F. limit: 1200 F. limit: 1000 F.
SPECIFICATIONS: Federal: HH-I-558a, Form C, Class- 10 and 11
A.S.T.M.: C-592, Class I and II
v . %.
-
ST00007-42 .
page 32
....................................
RECOMMENDED THICKNESSES *
HOT FACE
THICKNESS
1400 BLANKET
700F
2"
1000F
4"
1200F
5%"
1400F
?V
1200 BLANKET
500 F 800F
1%" . 3"
' 1000F 1200F
4" 6"
1000 BLANKET
300F 500F
1" 1%"
800F
3"
1000F
5"
*80F ambient still air.
HEAT LOSS 95 Btu 87 Btu 91 Btu 93 Btu 77 Btu 83 Btu 92.Btu 91 Btu 52 Btu 80 Btu 90 Btu 87 Btu
COLD FACE 130F
127F 129F 130F 122F 125F 130F 129F 110F 124F 128F 127F
|
Thermal Conductivity BTU in./hr. sq. ft. deg. F.
Mean Temperature 200 300 400 500 600 700 .28 .37 .43 .49 .56 .63
Application Secure mineral wool metal mesh blankets with No. 16 ga. monel wire or stainless steel bands to support rings, fasten edges of mesh together with clinch staples or 16 ga. monel wire. See M8A-203 Pg. 5.
Finish Indoor use - Apply hydraulic setting insulating cement 3/8" minimum thickness. See M8A-203 Pg. 1.
Flashing - Seal around projecting nozzles, supports, etc. with flashing mastic and glass fabric.
Outdoor Use - Over a cement finish apply two'1/8" layers of asphalt mastic with glass fabric between layers. See M8-561 or M8A-203 Pg. 2.
Alternate - Cover with protective jacketing. See M8-560 and 563.
,kM f
V*. :
ST 0000743
Pego
FIBERGLAS METAL I-HCH ?J..W?sT
1.0 Fiberglas Metal Mesh Blanket, insulation consists of a thick ness of fibrous glass wool facrd on one or both sides with wire mesh or expanded metal rib lath.
For uses on Dow equipment specifv type 900 with HT. facing (hexagonal mesh inside, expanded metal lath outside.)
2.0 TEMPERATURE RANGE:
Type 900 to 1000F
Type 600 to 400F
3.0 Expansion joints at 15' intervals should he provided where temperatures in excess of 600F. are encountered. Use manu facturer's recommendations.
4.0 SIZE DATA:
Thickness: 1" to 6" by V increments
Width:
12" to 24"
Length:
24" to 96"
Standard sizes are 24" x 96". Other sizes are made to order.
5.0 APPLICATION
Page 24 Recommended Thickness for Fiberglas Blanket Insulation
Page 119 Application of Blanket insulation on Horizontal Vessels 48" O.D. and larger
Page 121 Application of Blanket Insulation on Vertical Vessels 48" O.D. and larger
NOTE:
Expansion Joints for Blanket Insulation may be necessary for some installations. Obtain manufacturer's recommendations.
; ST0000744
pagp Z'h
GLASS FIBER PIPE INSULATION
1. 0 Material: Fiberglas Heavy Density Section Pipe Insulation is a molded pipe covering composed of Fiberglas wool resin bonded and formed in two half cylinders up to 12" IPS.
2.0 Temperature: -120F. to 450F.
3.0 Properties: Density: 7 lbs./cu. ft. (nom.)
Thermal Conductivity:
Mean Temp. F.
BTU/sq. ft. hr. F. /in.
50 .23 100 .25 200 .30 300 .36 350 .38
4. 0 Sizes: Available in 3 ft. long sections to fit all sizes of pipe and tubing from 1/2" IPS to 33". Thicknesses available in 1/2" increments.
5. 0 Jackets: Available with a number of factory applied jackets including FRJ (Fire Retardant Jacket) with self sealing lap. This cover provides a vapor seal for use on cold water lines and is sufficient for temporary or indoor service. The self sealing lap will not stick in cold weather and should be stapled. All outdoor lines should be further protected by a suitable weather barrier.
The insulation is available with a 4 oz. canvas jacket only on special order (requisition) except in 12 inch size which comes with canvas cover only.
6.0 Finish:
6. 1 Indoors
6. 1. 1 Concealed areas where insulation does not have to be protected from physical abuse, no finish is required. It may be finished with 4 oz. canvas (muslin).
6. 1. 2 Exposed areas where insulation is subject to washdowns, leaks, and other physical abuse, use outdoor finish as below.
6. 2 Outdoors - Use weatherproof finish.
ST00007U5
page 35
7.0 Manufacturers: Johns-Manville Owens-Corning - Fiberglas Heavy Density Sectional Pipe Insulation
Pittsburgh Plate Glass Gustin-Bacon
8. 0 Dow Uses:
8. 1 Traced lines (150 psig max. steam or hot water). See thickness charts.
8. 2 Hot and cold water lines 50F. and up, low pressure heating steam, condensate lines and personnel protection. See thickness charts.
8.3 Pilot plants, short-life, installations and temporary lines. See thickness charts.
9. 0 Application: For pipe, valves and fittings.
10.0
Weather proofing - moisture proofing - Glass Fibre insulation has the' ability to hold moisture against the pipe or vessel wall which will corrode the pipe or vessel. It does not absorb moisture but will hold moisture. Care must be taken to assure complete water proofing. Insulation must be clean and dry when applied. Pipe lines or vessels should be warm and dry when insulation is installed. A weather proof jacket should be applied over insulation immediately to insure insulation from getting wet.
NOTE: The owners of this insulation system should be informed of the above characteristic of Glass Fibre Insulation. (This is more or less a characteristic of all insulation; particularly when the temperatures are low. )
All breaks in the water proof jacket must be repaired immediately to avoid the absorption of water in the insulation.
ST00d6746
page 36
FOAMGLAS INSULATION
1.0 Manufactured by Pittsburgh Corning
2.0 Physical Properties
Temperature Limits Absorption of Moisture Add Resistance
-300F to +800 0.2Z by Volume Impervious to common acids and acid fumes
Capillarity
0
Coefficient of Expansion
0.0000046/F
Combustibility
Mill not bum
Composition
Closed glass cells completely Inorganic
Compressive Strength
100 Lb. per sq. in.
Density
9 lb./cu. ft.
Thermal Conductivity @
50F - 0.38 BTU/Hr. sq. ft. F./ in.
75F - 0.42 BTU/Hr. sq. ft. F./in.
3.0 Mon-Absorbent cellular construction.
4.0 Shapes available:
Curved Sidewall Segments (Tanks) Shaped Head Segments (Tanks) Valve and Fittings Covers Pipe Insulation
5.0 Pipe Sizes Available:
Horn, k" IPS through 36" IPS 1" through 4" thicknesses (single layer)
(Can also be furnished for double layer Installation)
ST 00007 47
page 37
CERAMIC FOAM
1.0 Manufactured by The Dow Chemical Company
2.0 Physical Properties:
Absorption of Moisture, (Z by Vol.) Acid Resistance Capillarity Chemical Resistance Combustibility Composition Compressive Strength, Avg. tilt. (PSI) Density, Average (PCF) Flexural Strength, Avg. Ult. (PSI) Linear Coefficient of Thermal
Expansion, (F) (75 F-400 F) (75F-1200F)
Maximum Service Temperature (F) Odor Shear Strength, Avg. Dlt. (PSI) Specific Gravity Specific Heat (BTU/lb.) Tensile Strength, Avg. Ult. (PSI) Thermal Conductivity
(BTU-in./hr.-ft.lcF) Avg. @ 40F Mean Temp. Avg. (3 75F Mean Temp.
Thermal Shock Resistance WVTR (PERM-inches)
.5 Excellent
None
Excellent Will Mot Hum
Inorganic
60
8
60
2.9 3.3
x x
10 10
. *.
-6
1,200
None 20
0.128
0.175 35
0.38 0.40 Excellent 0.00
3.0 Ceramic foam is a totally inorganic, rigid, closed cell vitreous material containing no fillers or binders. It is odorless and chemically inert, it is non-combustible resistant to solvent attack. It has no food value and will neither attract nor support animal or plant life. Concentrations of dust during fabrication and installing are within acceptable levels for nuisance dust.
4.0 Fabrication - Ceramic Foam has a high strength to weight ratio. Combined with excellent abrasion and impact resistance, material can be fabricated into shapes with commercially available saws, routers. For details of pre-cut vessel head blocks, see M8A-121.
5.0 Shapes Available:
Board Stock - 2, 3, 4 & 6 Tk. x 24" width x 36" long.
Billets - 4" width 24 x 36" 6" width 24 x 36" 8-3/4 width 17% x 36" 8-3/4 width 48 x 36"
; ST0000748
page 38
LOW TEMPERATURE PIPE AND VESSEL INSULATION
1.0 Material 1.1 StyrofoaidS' - extruded polystyrene foam plastic 1.1.1 Styrofoam F8 brand plastic foam is supplied in billet form to fabricators for production of precision pipe cover
ing.
1.1.2
StyrofoanP^ brand plastic foam boards:
PR, SM, and HD-FR (PZ 1623) 1.1.2.1 Styrofoam FR boards are
cut board stock used for insulating side walls of tanks.
1.1.2.2
Styrofoani^ SM boards are skinned
(molded) boards used for coating roofs and domes of tanks. It is stiffer than Styrofoam FR and harder to manipulate. It can be used for insulating the side walls of large tanks.
1.1.2.3
Styrofoam HD-FR (PZ 1623) boards
are designed for tank floor insula tion. It has a high load bearing capacity.
1.2 Thurane'0' brand plastic foam is a polyurethane plastic foam. xj. 1.2.1 Thurane^billets are supplied to fabricators for production of precision pipe covering.
1.2.2 Thurane0^ boards are used for tank insulation.
2.0 Temperature Range 2.1.1 Styrofoam
2.1.2 Thurane
-297F to +165F. -297F to 250F.
C
C
ST0.000749
page 3?
3.0 PROPERTIES
ASTM 3.1 Physical PropertiesTFCT_______________
1
STYROFOAM
J
FB , :?r
Sfl 1 THTJRAN7
ERANT)
ERAMb 'FRANb
PI.ASTT.C PLASTIC PLASTIC ! PJ.ASTIf
FOAM
: foam
FOAM.
FOAM
Density (lb./cu.ft.)
-!
Compressive Strength Avg. (psi at 5% deflection or yield)
D1621-64
3.2 Water Resistance Properties
1.8 25.0
i
j
11 i
1.8 30.0
2.2 2.0
30.02
25.0'
Water Absorption, % by Vol C-272-53
0.50
<0.10 <0.10 '. <0.11
Water Vapor Transmission
i
(perm-inch)
C355-64
1.0
1.0
0.6
1.0
Capillarity
-
None
None
None ! None
t
3.3 Thermal Properties
ii
Burning Characteristics
D1692-67 SE
SE
SE | SE
Flame Penetration
Bureau
*
*
* 1*
cf Mines
1|
Linear Cofficient of
1l
Thermal expansion(in/inF)
-260 F to +70 F
D696-44
2.6xl0-5
2.6xl0-5
2.6X10"5 l 2.3x10
Thermal Conductivity BTU/hr-sq ft F/in mean temp of 40 of
C177-63
ii
0.28 j
0.23
i
if 0.185 jo.15 F
Maximum Operating Temp (for continuous use),F
165 ! 165
165 j 250
^at yield
2 at 0.1 inch deformation
*Little or no resistance to flame penetration
3.4 Other Properties^ 3.4.1 Styrofoam*-^ 3.4.1.1 Protects low temperature pipes and tanks from condensation and water collection on the surface, a major factor in corrosion of the metal.
3.4.1.2 Excellent resistance to water absorption and to moisture vapor transmission.
3.4.1.3 Flame retardant
3.4.1.4 Blue color
3.4.1.5 Non-dusting - does not cause irritation to body during handling and fabrication.
ST0C00750
pa.'T.e AO
3.2.2
Thurane 3.2.2.1 Lowest thermal conductivity of
all commercial plastic foam insulations.
3.2.2.2 High resistance to water absorption
3.2.2.3 Fire retardant
3.2.2.4 Excellent resistance to solvents and chemicals.
4.0 Sizes 4.1 Styrofoani and Thurane pipe insulation Available in Nominal Pipe Sizes 1/2" through 30" in thickness 1/2" through 4" in 1/2" increments.
4.2 StyrofoanJ Boards
c
Styrofoam fr BRAND PIASTIC FOAM BOARDS
Styrofoam SM BRAND PLASTIC FOAM BOARDS
THICKNESS, INCHES
l. m 2,3,4 1, lii. 2,3,4
WIDTH, INCHES
16 16 24
%, 1.Hi. Hi. 2
24
LENGTH, FEET 9
4Vi,9
8
8
4.3 Thurane<S> brand plastic foam boards
THICKNESS, INCHES Yt, 1, \Vt, 2,3,4,5, 6
WIDTH, INCHES 16,24,48
LENGTH, FEET 4, 8,9
ST000075I
page ,lX
5.0 Finishes 5.1 Weatherable coatings or coverings are required
on outdoor insulated equipment. 5.1.1 Mastic coating systems or a metal jacket
may be used.
5.1.2
White or aluminum colored finishes are recommended over systems exposed to sun
light.
5.1.3 5.1.4 5.1.5
A protective covering should be provided over the insulation where mechanical damage is likely.
Thuranebrand plastic foam insulation
requires a vapor barrier coating on all equipment operating below ambient.
Styrofoam brand plastic foam installed
on dual temperature equipment requires a vapor barrier.
5.1.6 Solvent based mastics or coatings should not be applied directly to Styrofoam'S' . A base mastic of a type compatible with
C Styrofoam* should be applied with no pin holes, and allowed to cure properly, before applying the solvent base coating."'
5.1.7 Black colored mastics or coatings should not be applied over Styrofoam.
5.1.8
Almost all solvent adhesives and coatings, including polyester resin coatings, can be applied directly to Thurane .
5.1.9
Sunlight or even artificial light with a
significant ultravoilet spectrum will
~
gradually deteriorate the surface of Thurane .
Any finish or coating will afford an adequate
shield to ultravoilet.
5.1.10 Nearly all adhesives and coatings are compatible with Thurane due to its good
general solvent resistance.
6.0 Economic Thickness Charts 6.1 Styrofoam See page 25
6.2 Thurane- See page 26
r ST0000752
page 42
EXPANDED POLYETHYLENE INSULATION, ETHAFOAM
1.0 This material is a white, multicellular expanded poly ethylene, closed cell, flexible foam. Its suggested use as insulation is primarily in the low temperature field. It is flexible and can be bent around small vessels. Its advantages lie in its resistance to decomposition and low installation cost due to flexibility.
2.0 Physical Properties: K Factor-
.37 BTU/Hr./Sq. Ft. F/Inch, for all shapes.
Density-
1.9-2.6 Lb./Cu. Ft. for planks and 1.9-4.0 Lb./Cu. Ft. for Sheet and Tube.
Water Absorption .5 Lb./Sq. Ft. of Surface Area, maximum.
Water Vapor Transmission - 1.0 Perminch
Compressive Stress at 25% DeflectionContinuous - 160F. Intermittent - 190F.
3.0 Sizes:
The following sizes are available in nine foot lengths. For proper application thicknesses, consult Styrofoam thickness tables with consideration for slightly higher K factor.
Thickness 1 1/4"
1 3/4" 1 7/8" 2 1/2"
Tolerance 1/8" 1/4" 1/4" 1/4"
Width 14" 16" 24" 12"
Tolerance 1/2" 1/2"
1/2" 1/2"
The material is also available in 1/2", 3/4", 1", 2", 3", 4", and 6" rounds, and in a range of tubing sizes from 3/16" to 1 3/8" with 1/4" or 1/2" nominal wall thicknesses.
4.0 Availability:
Dow Chem. Co.
600 Northland Towers
15565 Northland Drive Southfield Detroit, Michigan 48235 Phone Number Area Code 313 444-1000
ST 0000753
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FOAMED-IN-PLACE POLYURETHANE INSULATION
1.0 Types of Foam 1.1 "MONO-FOAM," from Baldwin-Ehret-Hill, Federal Spec. HH-I-00530 (GSA-FSS), Blocks and Boards also.
1.1.1 (Standard) Type I, Class 2. 1.1.2 (Non-Burning) Type III, Class 2; by ASTM D-1692.
1.2 "EXPANDOFOAM," from Armstrong Cork Co.
1.2.1 System R109/R222H is standard.
1.2.2 System R110/R223H is fire retardant "Non-Burning," by ASTM test method D-1692.
1.3 "VULTAFOAM," from General Latex & Chemical Company. Non-Burning Fire Retardant Type, 16F-1202.
1.4 "MINIT FOAM," from Kerr Chemical, Inc., for elbows, fittings, small jobs, etc., in aerosol cans.
1.5 "INSTA-POAM FROTH PAK," Urethane foam in aerosol cans, from Insta-Foam Products, Inc.
1.5.1 A partially used can may be stored and later used to cb other jobs.
1.5.2 Nozzle Selection - shipped with two dispensing nozzles.
1.5.2.1 Fan spray (slotted) nozzle for coating surfaces.
1.5.2.2 Round opening nozzle for filling and caulking holes.
2.0 General Characteristics
2.1 Will adhere to most clean and dry surfaces except polyethylene, wax, and teflon.
2.2 Low thermal conductivity.
2.3 Low Moisture - vapor permeability. 2.4 Easy to Install.
2.5 Unaffected by fungus or mildew.
2.6 Long term performance,
2.7 Dimensionally stable.
2.8 Density - Free rise open box or form pour - 2 to 3 lbs. Densities Increase when foam is poured into a more re stricted space.
2.9 2.10
Closed Cells - (By volume) when properly foamed should be 80X to 952. Cell walls 2 to 2.52 - Open cells 2.5 to 102.
Temperature Range - Varies - Check Mfg. literature -200F. to + 140F.
-300F. to + 250F.
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2.11 Time
Hand mixing 15 to 30 seconds When air temperature and all component parts are at 70F, Rise time 3 to 4 min. Tack free time 3 to 4.min. Curing time 1 day
3.0 Care in Handling, Mixing, Foaming.
Do not inhale the Toluene diisocyanate vapors. Avoid pro longed contact with the eyes and skin. With reasonable care components are safe to work with in a well ventilated room or in outdoor locations. Handling, mixing and pouring of the foamed-in-place insulation shall be in accordance with the foam manufacturer's printed instructions.
4.0 Application.
All valves, fittings, flanges and other complex shapes shall be tested prior to application of insulation and shall be free of defects, dirt and foreign matter, and shall be thoroughly dry. A form shall be purchased or made to con tain the foam while being formed. This form may be a pre cast aluminum ell or tee or tuf-jac to serve as a permenent protection or a temporary removable form. The thickness of the foamed-in-place insulation shall be the same as the adjacent insulation.
When using a removable form, lubricate the inner surface of your form material with a parting agent to prevent sticking.
5.0 Finishes.
Weatherable coatings are required on outdoor installations. White is the preferred color for coatings that will be ex posed to sunlight. Protect with a white Polyethylene film or light gray P.V.C. film. Sunlight will degrade the sur face of the cellular structure.
Protect the surface of the foamed-in-place insulation in the same manner as the adjacent insulation.
Alternate finish - Apply 2 coats of Benjamin Foster 60 - 20 white safety monolar mastic reinforced with a layer of glass cloth.
Alternate 4010 mastic or "Thermotex" may be used over foam :' underground or where not exposed to the sunlight. M
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6.0 Weatherproofing Mastic, See M8-261
7.0 Metal Jacketing Steel vinyl coated, see M8-263 Aluminum, see M8- 264
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INSULATION SUNDRIES
1.0 The following materials are required in the application of piping and equipment insulations. Most of them are carried in Dow Stock and stock code numbers are listed accordingly. Other items which are not in Dow Stock must be purchased as required.
INSULATING CEMENTS
1. B-E-H No. 1 Plus Cement Dow Stock Code No. 200270
OR
A mineral wool, bentonite clay, and asbestos fiber cement for use up to 2100F. Supplied by Baldwin-Ehret-Hill
Co., in 50 pound bags. Coverage 25 sq. ft. at 1" thick per bag ASTMC-195.
Super "66u Cement OR
A mineral wool cement for use up to 1800F. Supplied by Eagle Picher Co.,
in 50 pound bags. Coverage 25 sq. ft. at 1" thick per bag.
MU No. 50 Cement
A mineral wool cement for use up to 1600F. Supplied by Philip Carey Mfg.
Co., in 50 lb. bags. Coverage 20 sq. ft. at 1" thick, per bag.
INSULATING FINISHING CEMENTS (Also known as "Blue Mud")
2. No. 303 Cement (or 7M) Dow Stock Code No. 200271
OR
An asbestos base finishing cement for use up to 1000F. Supplied by Philip
Carey Co., in 100 lb. bags. Coverage 19 sq. ft. at 1" thick per bag. Also known as 7M Cement.
No. 152 Cement OR
No. 352 Cement
OR
An asbestos base finishing cement for use up to 1000F. Supplied by Armstrong Cork Co. in 100 lb. bags. Coverage 19 sq. ft. at 1" thick per bag.
An asbestos base finishing cement for use up to 1000F. Supplied by Johns-Manville in 100 lb. bags. Coverage 19 sq. ft. at 1" thick per bag.
HW-One Cement
A mineral wool base finishing cement for use up to 1000F. Supplied
by Philip Carey Co. in 50 lb. bags. Coverage 20 sq. ft. at 1" thick per bag.
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HYDRAULIC SETTING INSULATING CEMENT
3. Superpowerhouse Cement Dow Stock Code 200264
OR
A hydraulic setting mineral wool cement for one-coat finishing on equipment and large pipes. Supplied by Baldwin-EhretHill Co., in 50 lb. bags. Coverage 55 sq. ft. at 1/2" thick per 100 lbs.
E.P. One-Cote Cement
Same as above. Supplied by EaglePicher Co., in 50 lb. bags. Coverage 75 sq. ft. at 1/2" thick per 100 lbs.
ASPHALT MASTIC EMULSION 4. Thermotex
Dow Stock Code No. 200263
OR
For weatherproof finish supplied by Philip Carey Co., in 50, 100, 300 and 500 lb. containers. Weight 10 lbs. per gallon. Coverage 55 sq. ft. at 1/4" thick wet per 100 lbs.
Insulkote OR
Johns-Manville in 50, 150 and 500 lb. containers. Weight 10 lbs. per gallon. Coverage 55 sq. ft. at 1/4" thick wet per 100 lbs.
90-07 H.I. Mastic
Benjamin Foster in 1, 5 and 55 gallon containers.
ALTERNATE: Fire Resisting Mastic, used at 794 Bldg. Insul-Caustic No. 551 (gray) vinyl-acryclic, 15 sq. ft. per gal. at 1/8" thick wet film, 10.3 lbs. per gal.
ADHESIVE CEMENTS
5. No. 340 Cement Dow Stock Code No. 200260
6. Plastic Elastlgum Dow Stock Code No. 300114
For cementing joints in Styrofoam and cork. Supplied by Armstrong Cork Co., in 1 and 5 gallon cans. Weight 12% lbs. per gallon. Coverage 30 sq. ft. per gallon, trowel application.
For applying hair felt and sealing laps of Weatherproof Felt. Supplied by Barrett in 10, 50 and 500 lb. containers. Weight 10 lbs. per gallon. Coverage 100 sq. ft. at 1/16" per 35 to 40 lbs.
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7. No. 81-71 Adhesive Dow Stock Code No. 200224
8. Flashing Insulmastlc No. 4010 Vaporseal Mastic Dow Stock Code No. 200247
02 Flashing Compound No. 9510 9. No. 5D-40 Adhesive
Dow Stock Code No. 200261
10. Sodium Silicate Dow Stock Code No. 300203
11. Careytemp Fibrous Adhesive
For cementing glass fiber in sulation on air ducts. Supplied by Benjamin Foster Co. (Ductfas) in 1 and 5 gallon cans. Coverage 150-200 sq. ft. per gallon. Drying time 10 - 15 rain. Flammable solvent.
Used with glass fabric to seal Weather proof mastic around nozzles and brackets Supplied by Pittsburg Coke and Chemical Co. in 1 and 5 gallon pails and 55 gallon drums. Coverage 10 sq. ft. at 1/8" dry thickness per gallon. Flammable solvent.
Benjamin Foster Co.
Used in spraying cork on Indoor piping and equipment. Supplied by Schermerhorn Paint Prod. Co., (Navy COticle) in 5 gallon palls. Coverage 10 sq. ft. per gallon for 1/2" thick cork. Water soluble.
Used with Asbestos Cement to adhere insulation to metal surfaces. Use 40 Baume type. Supplied in 50 gallon drums.
An asbestos fiber and silicate of soda fibrous plastic cement for use up to 800F. Supplied by Philip Carey Co. in one and five gallon palls and 55 gallon barrels. One gallon covers 25 - 30 sq. ft. at 1/8" thickness.
12. Pittsburgh-Coming's Pittseal 111
Used for bedding cellular insulations and as a sealer in expansion joints. It cushions insulations against abrasion and seals joints against vapor leaks which might cause condensation and freezing. Aluminum in color. Temp erature range of -100F. to +300F.
Supplied by Foamglas distributors in one and five gallon containers. One gallon covers 26 sq. ft. at 1/16" thickness or 13 sq. ft. at 1/8" thickness.
ST0000759
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FASTENING MATERIALS
13. Staples, Copper Clad Flat, 12 Ga.
Dow Stock Code No. 200257
Dow Stock Code No. 200258
Dow Stock Code No. 200259
For fastening pipe covering. Supplied in 100 lb. boxes. (Jennison Hardware Co.)
Size 3/4" x 1/2", 350 pcs. per lb.
Size 1" x 3/4", 185 pcs. per lb.
Size IV x 1", 140 pcs. per lb.
r. ST00007 60
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14. Banding, Stainless Steel Dow Stock Code No. 200131
15. Seals, Stainless Steel Dow Stock Code No. 200132
16 Wire, Copper Dow Stock Code No. 775187
17. Wire, Monel Dow Stock Code No. 048116
18. Screws, Sheet Metal Dow Stock Code No. 577203
19. Wire Netting, Hex Mesh Dow Stock Code No. 200254
20. Tape, Filament Dow Stock Code No. 200313
21. Tape, Pressure Sensitive Dow Stock Code No. 200223
22. "Zeston" Z-Tape
For fastening insulation. Size 5/8" x .01?" Type "304" thick in 200 ft. rolls'.. Supplied by A. J. Gerrard & Company; for seals, see Item 14.
For use with stainless steel banding. Supplied by A. J. Gerrard 6 Company. No. 1523, closed type, SS, 5/8" x 7/8".
For fastening insulation. No. 12 Gauge, Soft. Furnished in 25 Dound soonIs.
Order soft annealed, supplied in rolls. Dia. .064" No. 16 Ga.
For fastening 26 Ga. galvanized steel sheets. Use Size No. 7 (.151" Dia.) x V, RH, Pan Head self tapping cadimum plated sheet metal screws Parker-Kalon or approved equal. Supplied in 1 gross boxes. Use 7/64" drill.
For reinforcing Insulating cements and asphalt mastics. Order 20 ga., T'hex mesh,"galvanized after weaving." Furnished 48" wide in 150 ft. rolls. Also known as Poultry Netting.
For fastening sectional Styro foam pipe insulation. No. 880 "Filament Tape" 3/4" wide, supplied by Minnesota Mining & Mfg. Co. in 60 yard rolls.
For sealing joints in glass fiber duct insulation. 2" wide supplied by Permacel Tape Company in 60 yard rolls.
10 mil polyvinyl chloride film bonded with a specially formulated adhesive that can be applied in doors or out at temperatures as ' low as 20F. to make a strong1<jfev>i permanent bond joint.-'EffectiySfinJ stalled temp, range .of. 175 Available & 3" standard lengfh^'flO^J^^B^^j
' ST000076
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23. Skewerb. Wood
Dow Stock Code No. 200311 Dow Stock Code No. 200312
For fastening layers of Styrofoam. Supplied fy Arrcstrorg Cork Company (also from butcher supply companies) 1-1/64" Dia. x 4V'. Wt. 5 pounds per M. h" Dia. x 5%", Wt. 6.5 pounds per M V' Dia. x 7", Wt. 10 pounds per M.
24. Paste, Cold Water Dow Stock Code No. 200262
For Pasting Osnaburg Png over in sulation. Also called "Dry Paste". Supplied by Jennison Hardware Co., in 100 and 5 lb. bags.
JACKETING 25. Weatherproof Felt Firetard Jacket
Dow Stock Code No. 200266
OR
For weather protection of in sulation. Supplied by Johnsmanville in 55 pound rolls, 32" wide x 40 ft.- long. Coverage 100 sq. ft. per roll. Order Whiteside out, rolls in one piece, felts only. Also known as "Black and White" felt. Outside use.
Weatherproof Felt Fireclad Jacket
For weather protection of in-- sulation. Supplied by Philip Cary Mfg. Co., in 50 pound rolls 38" wide. Coverage 108 sq. ft. per roll. Order Whiteside out, rolls in one piece, felts only. Al9o known as "Black and White" felt. Outside use.
26. Osnaburg Rag Dow Stock Code No. 770129
27. Glass Membrane Fabric Dow Stock Code No. 200246
For covering insulation. Order Furnished in bolts or rolls 40" wide, in varying lengths, as required. Inside use only.
For reinforcing asphalt mastic weatherproofing. Open weave, 36" wide x 50 yard rolls. Supplied by Twinsburg-Miller Corp. (Glasfab) Inside or outside use.
OR
An open mesh glass fabric, (wrap 100 lb., Fill 75 lb.), supplied in 50 yd. rolls in widths of 6", 18", 36" and 45"; Insul-Mastic Corp. of America. Inside or outside use. ''
ST0000762
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28. 10 oz. Fiberglas Cloth Volan "A" Treated Style 7500 Supplied by Cadillac Plastic
For use with Epoxies on equipment. To produce a hard finish over in sulation. Glass cloth with a plain weave. 50" in width x 125 yd. roll, 16 x 14 thread average thickness 13 mils break strength 450 x 410 mfg. for marine and tooling field. Inside or outside use.
29. 6 oz. Plastic Sheet Dow Stock Code No. 200015
"FILON" No. 950 clear, flat plastic sheet, size: 3` x 10' x .045" thick. (Approx. $.60 per sq. ft.). Used to replace galvanized sheet metal on columns, towers, tanks, in highly corrosive areas. Inside or outside use.
30. Dynel Modacryllc Fabric
A porous woven reinforcing fabric used as an overlay for reinforced plastics to give a tough, abrasion resistant, chemical resistant, durable surface. Supplied by Union Carbide Corporation. Inside or outside use.
31- P.V.C. Pre-Molded One Piece Pipe Fitting
"Zeston" molded pre-cut P.V.C. fitting that snaps quickly into place over pre-cut insulation and is held firmly in position by two simple metal bands. Available in 90 , 45 , tees, valves, reducers, end caps, hub joints and long radius elbows in most commonly used sizes from Zeston, Inc. Inside or outside use. (See Design Aid M8-427)
32. P.V.C. Piping Jacket
"Zeston" P.V.C. jacketing is supplied in 600 sq. ft. rolls that can easily be cut to size and stapled or tacked to the in sulation material with "Zeston's" tack fasteners and heat sealed. Alternate fastening method - use Zeston Z-Tape available from Zeston, Inc. Inside or outside use.
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33. Tuf-Jac^Coated Steel Jacketing. Insul-Coustic Division, Birina Products Corp.
Class 561 Code 200151
Or Steel Jac Coated Steel Jacketing. Childers Products Company, Division of Smith Products, Inc. 34. I-C Stainless Steel Jacketing
MISCELLANEOUS 35. Cork, Granulated
Dow Stock Code No. 200272
3$. Styrofoam, Granulated
37. Tape, Asbestos Listing Dow Stock Code No. 020101
Mild steel with electrogalvanized baked on orgar.asol protective coating. Melts at 2400 F. Available in 36" wide by 50' and up rolls with smooth or corrugated finish for piping and equipment and deep corrugated sheets 1*5" x 2h" pitch, deep corrugated along length of sheet to 12' lengths with smooth or cross-crimped finish for vertical tanks and vessels. For details see P2Q6 58.
301 or 302 alloy stainless steel. 316 alloy available as special item only. Melts at 2400 F. Supplied by Insul-Coustic Division, Birina Products Corporation. Available in 36" wide by 50' and up rolls with 2-B smooth or corrugated finish for piping and equipment and deep corrugated sheets
IV* x 2Ji" pitch, deep corrugated
along length of sheet to 12* length.? with smooth or cross-crimped finish for vertical tanks and vessels.
For filling voids in cork insulations and for spraying on pipes and equip ment. Size 8-14 mesh. Supplied by Armstrong Cork Company, in 7 cu. ft. bags weighing approximately 35 lbs.
Manufactured by Dow and available on order at 542 Bldg. Order Grind "A" type. Furnished in 10 cu. ft. boxes containing 15 - 18 lbs.
For wrapping exposed copper tubing. Size .025" x 1" wide, woven white asbestos. Johns-Manville 2025.
: S T 0 0 0 0 7 6 4,
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38. Gilso Card or Gilso Therm Dow Stock Code Mo. 200166
For insulating pipes buried directly in ground. Supplied by American Gilsonite Company, in 100 lb. bags
41. 5/8" Braided Asbestos Tubing Dow Stock Code Mo. 200117
42. Armstrong '-Armaflex" Pipe Insulation
For improving performance of steam tracing. ''Zeston'', "Thermon", or approved equal. Coverage - .33 lbs. per linear foot of 1/2" tracer tube. Supplied in 1 and 5 gallon pails. Weight 14 pounds per gallon.
A poly vinyl acetate mastic for use up to 180F. Supplied by Insul-Coustic Division, Birma Products Corporation. One gallon covers 12 - 15 sq. ft. at 1/8" thickness.
Used to slip over 1/2" and 3/8" copper tube tracer along process lines to keep lines from touching each ocher. Also where tracer is used along instrument lines to stop hot spots, etc.
A flexible foamed plastic insulation to be slipped over pipes and tubing to prevent condensation on liquid cooling and heating lines, chilled water, and other cold lines. Avail able in 6 foot lengths in 3/8" wall thickness for all pipes and tubing through 1-3/8" O.D., and 1/2" wall thickness for pipes and tubing through 3-1/8" O.D. Temperature Range: 1/2" wall thickness - 327F.-20oV 3/8" wall thickness - 50F. - 200F.
A low-density polyethylene foam which remains soft and flexible up to 150F. used for insulating chilled water and refrigeration equipment lines to pre vent surface condensation. It may be slipped over pipes or tubes with bends up to 45. Available in 6 ft. lengths in 3/8" or 1/2" wall thickness for 3/8" , .
ST0000765
pa^e 55
STAPLE JACKET FASTENING PROCEDURE
1.0 Scope
1.1 An effective way of fastening asbestos paper to insulation is to use a staple gun and monel staples.
2.0 Staple Guns Available
2.1 Hand Stapler
2.1.1 Recommended for use on small jobs or in areas where an electric or pneumatic stapler cannot be used.
2.1.2 Bostitch Model T-580-C2 with Standard Spring.
2.1.3 Use 1/2" leg length Monel Outward Clinch Staples .050" wide x .019" thick.
2.2 Pneumatic Stapler
2.2.1 Requires an 80 psi air supply to operate.
2.2.2 Bostitch Model SBNK
2.2.3 Use 1/2" leg length Mor.el Outward Clinch Staples .040" wide x .023" thick.
2.3 Electric Stapler
2.3.1 Duo Fast Model Ho. F.V-5018-0C Tacker.
2.3.2 Use 9/16" leg length Monel Outward Clinch Staples Mo. 5018C, .050" wide x .019" thick.
3.0 Application
3.1 The staples should be applied every two inches.
3.2 This sene procedure is recommended for use on the self sealing lap of Fiberglas insulation in extremely cold weather.
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PRE-CUT WEATHERPROOF FELT WITH SELF SEALING LAP
1.0 Scope
Pre-cut and pre-rolled sections of jacketing paper for pipe insulation are available. These sections are very advantageous for new construction jobs and offer an appreciable savings in application time.
2.0 Material
2.1 The.jacketing is asphalt saturated Inorganic felt with a white flame-proof laminate, approximately .030" thick, and reinforced with glass fiber strands spaced on V centers laid circumferentially.
2.2 The inner face of the lap has a sealer of synthetic adhesive, l*s" wide, .002" thick, with a treated paper release tape.
2.3 The outer face of the lap edge is printed with a pattern in dicating the proper spacing location of the attaching staples. (See M8A-408).
3.0 Sizes Available
3.1 The jacket is preformed to fit various pipe sizes with 3/4", 1", Us", 2", 2Y' and 3" thicknesses of pipe insulation.
4.0 Ordering Information
4.1 These pre-cut and pre-rolled sections of jacketing paper are available from Industrial Insulation, Inc., Bay City, Michigan
4.2 In ordering this paper specify the following:
4.2.1 Pipe size.
4.2.2 Thickness of Insulation.
4.2.3 Length of pipe line.
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SELECTION OF METAL JACKETING
1.0 In order to design an optimum jacketing system, the various metals currently used must be discussed.
1.1 Stainless Steel: (T301 or T302 & T304 & T316)
1.11 Advantages are:
1.111 1.112 1.113 1.114
High corrosion resistance High melting point (2800<'F) Low maintenance cost
Low heat emissivity
1.12 Limitations are High Cost.
1.2 Vinyl coated Electro-Galvanized, "Tuf-Jac" or "Steel-Jac."
1.21 Advantages are:
1.211 No glare 1.212 Good fire retardence 1.213 Good mechanical strength
1.22 Limitations are that organic coating will char at incendiary conditions, but will not support combustion.
1.3 Epoxy or Acrylic coated Aluminum.
1.31 Advantages are:
1.311 Choice of colors 1.312 Intermediate corrosion resistance
1.32 Limitations are:
1.321 Organic coating will support combustion 1.322 Tendency to discolor
1.4 Aluminum (.016" Ga.) with moisture barrier.
1.41 Advantages are:
1.411 Low material cost 1.412 Installation ease
1.42
Limitations are:
'
1.421 Low melting point
1.422 Limited use in chemical atmosphere
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SELECTION OF PROTECTI'42 STEEL JACKETING
1.0 Available in a variety of forms as follows:
1.1 In rolls.......... for field application - in either smooth of "Super Strength" corrugation...comes in sizes of 36 inches in width and 50, 75 or 100 feet in length.
1.2 In pre-cut and pre-rolled.......... metal clad with a deep Pittsburgh logitudinal joint and matching butt joint sealer strip. It is accurately cut'and rolled to fit pipe insulation sizes up to 24 inches IPS x 3 inches thick insulation.
1.3 In panels.......... deep corrugated (1% and 2% inch pitch) available in 33 inch widths and 6, 8, 10 and 12 feet lengths - ideal for tank insulation and building panel work.
2.0 Advantages are:
Maximum impact resistance, good weather durability, and it has a polyethylene galvanic barrier heat-seal laminated to under side. Multi-stage protective finish, toughness of steel, fire resistivity, and low cost are others.
3.0 Workability factors are:
Easily worked with conventional hand tools and applied similar to other types of insulation jackets.
4.0 Metal finish contains:
Electrogalvanized, chemically treated, and resistant enamels.
5.0 Color is gray with special colors available.
PHOSPHXrt OR COHVtUtO* COATING
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6.0 Thickness of metal is 0.010 inches. 7.0 Acceptable makes are Smith Products, Incorporated "Steel-
Jac," and Insul-Mastic Corporation "Tuf-Jac."
8.0 Application 8.1 Lap all joints one corrugation when installing (lSj" and 2H" pitch) panels. 8.2 Lap 2" on all joints when installing the smooth or low corrugation material. 8.3 Secure in place using a No. 7 x h" long pan head cadmiumplated, self-tapping sheet metal screw on 4" centers.
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ALUMINUM JACKETING FOR THERMAL INSULATION
1.0 Available in a variety of forms.
1.1 Roll Jacketing
Alloys - type 3003 (3s) type 5005 (5s) with E-14 temper
1.2 Moisture Barriers
30-90-30 Duplex laminated moisture barrier. It is a uniform film of oxidined asphalt laminated between two 100% Virgin Kraft sheets. Softening point of asphalt 180 to 200F, flash point of 550F.
1.3 Poly Kraft
Polyethylene coated kraft paper. One layer of 50 lb. paper coated on one side with 1 mill polyethylene film. The kraft paper is attached to the underside of aluminum using an adhesive across full width of the jacketing. Softening point of polyethylene coat 300 to 320F, flash point of 500F
1.4 Thickness
.010 recommended corrugated for use on pipe lines up to 24" O.D.
.016 recommended corrugated for use on pipe lines, tower vessels and tanks up to 15' in dia.
1.5 Roll Sizes
.010 or .016" Tk x 36" x 100 ft. = 300 sq. ft. roll .010 or .016" Tk x 48" x 100 ft. = 400 sq. ft. roll
1.6 Corrugated Sheets
Thickness .016", .019", .020", and .024" Corrugations IV and 2*s" Widths 33" and 44" x 6,8,10, and 12' long For insulating towers, vessels, and tanks 16 ft. in dia. or more.
2.0 Application of Aluminum Sheet on Vessels
2.1 Apply - 0.016 thick type 5005 H-14 cross crimped aluminum jacketing with integral poly kraft (polyethylene - kraft paper) moisture barrier. '
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2.2 Install the aluminum sheets so they will shed water. Secure the aluminum sheets with aluminum screws or pop rivets spaced on maximum 6" centers for vertical seams and 9" centers for horizontal seams.
2.3 Install 3/4" wide by 0.020" thick aluminum bands on 24" centers over the aluminum jackets. To prevent the bands from slipping, attach same to the aluminum jackets with 3 aluminum clips, screws, or pop rivets per band, spaced 120 apart.
2.4 Flashing - Seal around projecting nozzles, supports, etc. for weatherproof finish.
2.5 On vertical vessels place aluminum "Z" clips on the upper perimeter of each sheet of aluminum. Space clips on maximum 24" centers.
2.6 The aluminum jackets must not be installed in contact with steel.
2.7 Over calcium silicate or other alkaline insulation, it is imperative that any damaged moisture barrier on the aluminum jacket is patched before being applied. Do not allow the bare aluminum to contact calcium silicate or other alkaline insulation.
3.0 Aluminum has a limited use in some chemical atmospheres.
3.1 It requires protection from most acids and alkalis. Aluminum is now available pre-coated in colors with, vinyls, epoxies and phenolics when color is desired or when the environment demands it.
3.2 Check location and ambient conditions with the Materials Engineering Department before specifying aluminum.
4.0 Acceptable makes
4.1 Childers Manufacturing Co., Houston 8, Texas
4.2 Al-Cor-Jac Insul-Coustic Corporation
SELECTION OF MASTIC JACKETING
1.0 TYPES: 1.1 Asphaltic Type
A weather-barrier type mastic for troweling. Applies easily. For use as a finish over insulating cements. Flashing mastic used to seal nozzles and brackets.
1.1.1 Breathing Type
Thermotex - B
Philip Carey Company
Dow Stock Code No. 200263
Insulkote ET
Johns-Manville
90-07 H.I.Mastic
Benjamin Foster
1.1.2 Sealing Type
Flashing Insulmastic No. 4010
Pittsburgh Coke and Chemical Company
1.2 Polymeric Type Vinyl and Acrylic type latexes. A semi-vapor barrier mastic for trowel or spray. Easily applied, provides excellent mechanical and weather resistance.
"Benjamin Foster GPM 35-00
Benjamin Foster
Vimasco WC-1
Vimasco
Insul-Coustic VI-AC 551
Birma Products Corp
Vi-Cryl CP-10 and CP-11
Childers Products Company.
1.3 Elastomeric Type
A vapor-barrier type mastic. Provides excellent mechanical and weather resistance. Can be used as an overcoat with GPM @35-00.
Benjamin Foster Manolar 60-36.
Eenjamin Foster
Benjamin Foster Mastic 60-30
Benjamin Foster
Benjamin Foster Mastic 60-35
Benjamin Foster
D.C.Silicone Rubber Dispersion Dow Corning
. ST0000773
page 63
c 2.0 Before application, the insulator must acquaint himself with the product being handled, such as:
2.1 See Manufacturer's Specifications for handling: Trowel, spray or brush grade - summer or winter grade.
2.2 Classification: as to fire, flame spread and flash point, temperature limits, safety.
2.3 Type of Volatile: Water or solvent.
2.4 Material Preparation.
2.5 Limitation of Materials.
3.0 CAUTION:
These coatings shall not be applied to surfaces containing frost or moisture, oil, grease, chemicals, wet cement or scale. Any of these will interfere with adhesion.
5.0 Application of Weatherproofing:
5.1 Apply 1/8 inch minimum thickness of
mastic;
while wet, imbed a glass or Dynel membrane into
the mastic to insure complete and uniform contact.
Smooth out all wrinkles and follow with a 1/8 inch
final layer of asphalt mastic.
5.2 Alternate: When tanks, vessels or heat exchangers are subject to expansion and contraction, apply one inch hexagonal wire mesh laced on smooth and tight. Then apply two 1/8 inch layers of mastic troweled to a smooth finish.
5.3 Flash all nozzles, brackets, lugs or any projection throuqh the insulation at flanges, platforms, etc. See page 151.
C
r -r r\ i-'
i^
^
^ 7 "M
w / / **
par.c 6H
AT "jICATICr OF E^Oir:: CRATING
1.0 Scope
1.1 This practice shall servo as a guide only as each specific job must be altered to suit field conditions.
1.2 For additional information on the uso of Epoxies and Derakancs (Vinyl Ester Rosins), call Materials Engi neering, Coatings Section.
1.3 Multiple layer laminate - On a firm substrate such as Foamglas and other block, a two layer laminate should be adequate. In traffic areas or where hard finish is subject to abuse, an added layer may be necessary.
2.0 Insulation
2.1
Application of insulation and filler material shall be as previously specified with all joints pointed up, all voids filled, and covered with a coat of cement in preparation for the rosin finish.
3.0 'Epoxy Coating Materials
3.1 Glass cloth specifications;
10 oz. fiber
glass cloth No. 7500 Volan treated 16 x 14 thread,
13 mil thickness, plain weave, 50 in. wide x 125 yds. in
roll. Supplied by Cadillac Plastic.
3.2 Dow Epoxy D.E.R. 331 resin in .stock at Materials Center in gallons.
3.3 DETA Hardner in stock at Solvent Stock.
3.4 Use 10 to 11 parts by weight of DETA per 100 parts of DER 331.
4.0 Application of Epoxy and Glass Cloth for Hard Finish
4.1
Wet the cemented surface with Dow Epoxy. Stretch on the first layer of glass cloth and roll it on to saturate the back side of the cloth. Extend glass cloth and epoxy up 3" around all nozzles and allow 6" lap over body jacket to protect against chemical spills. Over lap glass cloth 3 to 4" and stagger all joints.
4.2
Apply resin to top side of the cloth, work into thor oughly saturate the cloth, work out all bubbles. If white spots appear, it is lack of saturation. Allow time for curing at a minimum temperature of G0F.
ST0000775
page 65
C 4.3 As'soon as the first layer is firm enough to work on, apply the second layer of cloth in the same manner. Too long a time interval between layers will result in poor adhesion.
4.4 After the laminate system has hardened, hand sand (using a sanding block) remove irregularities, rough spots and frayed edges of the cloth.
4.5 Apply a finish coat of Epoxy.
5.0 Curing Time
5.1 The resin system must have adequate curing temperature at 60eF for several days. If temperatures are lower than 60F, provide closures and/or other facilities for curing. Curing time is less at higher temperatures.
c
c
;ST0000776
page 66
Dimension Standards . Insulated NPS Pipe
In. the development of the insulation industry the major manufacturers produced pipe insulation to their own specifications. This, of course, resulted in a hodge podge of pipe sizes. There was a definite need for a standardization of sizes as well as a need to have the outside diameter of each piece of insulation equal to the outside diameter of standard nominal pipe sizes (NPS). In this way, multiple layered insulation could be fitted by using the appropriate next larger pipe size. This system has been adopted by the major producers of pipe insulation and is known as ASTM Standard C- 521. The dimensions for both NPS pipe and tubes are shown in the following tables.
^NPSNOMINAL INSULATION THICKNESS
.* flvR
a. W THK. | O.D.
1" THK. 1 O.D.
mm THK. | O.D.
2ft THK. O.O.
VA" THK. O.D.
a H
1
. U4
r IK
2
2K 3
3K 4 5
.84 .53 1.05 .66 U2 .53 1.66 .61 1.90 .49 2.38 .56 2.88 .56 3.50 .50 4.00 .50 4.50 .53 5.56 .53
1.90 1.02 2.88 1.58 2J8 .91 2.88 1.48 2.38 1.09 3.50 1.59 2.88 .92 3.50 1.67 288 1.05 4.00 1.53 3.50 1.06 4.50 1.59 4j00 1.06 5.00 1.87 4.50 1.03 5.56 1.56 5.00 1.31 6.62 1.81 5.56 1.06 6.62 1.56 6.62 1.03 ~ 7.62 1.53
4.00 2.08 4.00 1.98 4.50 2.12 5.00 1.95 5.00 2.% 5.56 2.12 6.62 2.37 6.62 206 7.62 2.31 7.62 2.06 8.62 203
5.00 289 6.62 5.00 279 6.62 5.56 2.65 6.62 5.56 248 6.62 6.62 286 7.62 6.62 2.62 7.62 7.62 287 8.62 7.62 2.55 8.62 8.62 2.81 9.62 8.62 2.55 9.62 9.62 2.59 10.75
6
6.62 .50
7.62 1.00
8.62 1.50
9.62 206 10.75 256 11.75
3
8.62 .50
9.62 1.06 10.75 1.56 11.75 206 1275 268 14.00
10 10.75 .50 1175 1.00 12.75 1.63 14.00 2.13 15.00 2.53 16.00
12 12.75 .63 14.00 1.13 15.00 1.63 16.00 2.13 t7.00 2.63 18.00 14 - 14.00 .50 15.00 1.00 16.00 1.50 17.00 200 18.00 2.50 19.00
16 .-. 16.00 .50 17.00 1.00 18.00 1.50 19.00 200 aoo 2.50 21.00
18 18.00 .SO 19.00 1.00 20.00 i.50 21.00 2.C3 22.CC ?.50 23.03
aoo20 20.00 .50 21.00 1.00 aoo 1.50 23.00 200 24.00 2.50
aoo22- . 22.00 .50 -
1.00 24.00 1.50 aoo 2.00 aoo 250 27.00
24 24.00 .50 25.00 1.00 aoo 1.50 27.00 2.00 28.00 2.53 29.00
26 26.00 .50 27.00 1.00 aoo 1.50 aoo 2.00 aoo 250 31.00
28--* 28.00 .50 aoo 1.00 30.00 1.50 31.00 200 aoo 2.50 a.oo
30 v 30.00 .50 31.00 1.00 32.00 1.50 aoo 200 34.00 2.50 35.00
r
THK. O.D.
3.39 7.62 3.29 7.62 3.15 7.62 298 7.62 3.36 8.62 3.12 8.62 3.37 9.62 3.06 9.62 3.37 10.75 3.12 10.75 3.10 11.75 3.06 1275 3.18 15.00 3.13 17.00 3.13 19.00 3.00 aoo 3.00 aoo 3.00 24.00 3.00 aoo 3.00 aoo 3.00 aoo 3.00 aoo
3.00 aoo
3.00 aoo
3Vi' 4m
THK. O.D. THK. O.O.
3.89 8.62 4.39 9.62
3.79 8.62 4.29 9.62
3.65 8.62 4.15 9.62
3.48 8.62 3.98 9.62 3.86 9.62 4.48 10.75 3.62 9.62 4.18 10.75 3.94 10.75 4.44 11.75 3.62 10.75 4.12 11.75 3.88 11.75 4.38 1275 3.62 11.75 4.12 1275 3.59 1275 4.22 14.00
3.68 14.00 4.18 15.00
3.68 1600 4.18 17.00
3.63 18.00 4.13 19.00
3.63 aoo 1 4.13 21.09 , 3.50 21.00 4.00 22.03 |
3.50 23.00 4.00 24.00 |. 3 50 25.09 4.00 25.00 | 3.50 27.00 4.00 aoo |
3.50 aoo 4.00 aoo |
3.50 31.00 4.00 aoo
3.50 aoo 4.00 aoo 3.50 aoo 4.00 aoo 3.50 aoo 4.00 aoo
NON--Nominal Dtamtiar 0.0.--Actual Outaide DIamatir (lachts) THIC--Actual Thickness at Insulation (Inchn)
c
This table is used to convert tbe nominal insulation thickness to the proper dimension standards for insulated NPS Pipe. For 2 inch NPS pipe with 3 inches of insulation a sin|le layer 3.12 Inches with an 0.0. ol 8.63 inches would be used. The two layer desipi would require one 1.J3 lack thickness with 0.0. el 5.66 inches and one 1.S3 inch thick coverini with an 0.0. of 1.63 inches. The second layer actually has an t.D. correspondini to the O.D. of 5-inch NPS pipe end could be used as coveriet for that sirt. The actual thickness ol the two layer desitn would be 3.12 inches.
Table 4-1
E ST'O0CT0777
pcf.c 67
PIPE ~ND TUBE INSULATION DIMENSIONS
BASIC OUTSIDE DIAMETERS FOR TUBE INSULATION ASTM Recommended Practice
Tube Size
O.D.
1/4 0.250 V8 0.375 1/2 0.500 1/2 0.625 3/4 0.750
3/4 0.875 1 1.000 1 1.125 Ik 1.250
l*s 1.500 1% 1.625 ? 2.000
2.125
"'H 2.500
3*s 3
3
3 5/8 1
2.625 3.000 3.125 3.625 4.000
4 4.125 5 5.000 0 5.125 5 6.000 5 6.125
> or\ .uuu 3 8.125 10 10.000 10 10.125 12 12.000
14 14.333 16 16.333 18 18.333 30 20.333 34 24.333
1/2
1.315 1.660 1.660 1.660 1.900
1.900 2.375 2.375 2.375
2.875 2.875 3.500 3.500 3.500
4.000 4.000 4.500 5.000 5*000
5.563 6.625 6.625 7.625 7.625
Nominal Thickness of Insulation
1 " 1% ' "~Z "..........2h
3 "*"3*r..............
2.875 2.875 2.875 2.875 2.875
3.500 3.500 3.500 3.500 4.000
4.500 4.500 4.500 4.500 5.000
5.625 5.625 5.625 5.625 5.625
6.625 6.625 6.625 6.625 7.625
7.625 7.625 7.625 7.525 8.625
4
8.625 8.625 8.625 8.625 9.625
3.500 3.500
3.500 3.500
4.000 4.000 4.000 4.500
5.000 5.000 5.000 5.563
6.625 6.625 6.625 6.625
7.625 7.625 7.625 7.625
3.625 8.625 8.625 8.625
9.625 9.625 9.625 9.625
4.000 4.000 4.000
4.500 4.500
4.500 4.500 5.000 5.563 5.563
5.563 5.563 6.625 6.625 6.625
6.625 6.625
7.625 7.625 7.625
7.625 7.625 8.625 8.625 8.625
8.625 8.625 9.625
9.625 9.625
9.625 9.625 10.750 10.750 10.750
5.000 5.000 5.563 6.625 6.625
5.563 6.625 6.625 7.625 7.625
6.625 7.625 7.625 8.625 8.625
7.625 8.625 8.625 9.625 9.625
8.625 9.625 9.625 10.750 10.750
9.625 10.750 10.750 11.750 11.750
10.750 11.750 11.750 12.750 12.750
6.625 7.625 7.625 8.625
8.625
7.625 8.625 8.625 9.625 9.625
11.750 11.750 12.750 14.000 15.000
8.625 9.625 9.625 10.750 10.750
12.750 12.750 14.000 14.000 16.000
9.625 10.750 10.750 11.750 11.750
14.000 14.000 15.000 15.000 17.000
10.750 11.750 11.750 12.750 12.750
15.000 15.000 16.000 16.000 18.000
11.750 12.750 12.750 14.000 14.000
16.000 16.000 17.000 17.000 19.000
12.750 14.000 14.000 15.000 15.000
17 non
A/
17.000 18.000 18.000 20.000
18.000 20.000 22.000 24.000 28.000
19.000 21.000 23.000 25.000 29.000
20.000 22.000 24.000 26.000 30.000
21.000 23.000 25.000 27.000 31.000
33.000 24.000 26.000 28.000 32.000
23.000 25.000 27.000 29.000 33.000
1
Table 4-2
i.ST 0000778
page 68
APPLYING SINGLE LAYER RIGID PIPE INSULATION
(
APPLICATION PROCEDURE
1.0 O. D. Insulation Use a lagging adhesive to fasten on the canvas jacket. sizes up to 12" Glass fiber adhesive tape may be used on cellular glass. Any voids shall be pointed up with insulating cement
2.0 O. D. Insulation sizes over 12"
Fasten the sections with stainless steel banding (5/8" x .015). Spacing of bands shall be approximately 12" apart with no band more than 4" from an end joint. Any voids shall be pointed up with insulating cement.
3. 0 Indoor Finish
On sizes under 12" O. D. cover with Osnaburg Rag using a lagging adhesive. O. D. insulation sizes over 12" shall always be finished with a weatherproof cover.
4.0 Weatherproof Finish
Apply weatherproof felt as shown on pagel02 or an equivalent metal finish as shown on page 103-
5.0 Fittings
Use premolded elbows covered with canvas or as shown on pages 74 and 76 .
C
\ STO000779
pa^.e 69
APPLYING DOUBLE LAYER RIGID PIPE INSULATION
1.0
2.0 3.0 4.0 5.0
APPLICATION PROCEDURE
O. D. Insulation sizes up to 12"
Remove canvas from inner layer with joints and seams staggered. Use a lagging adhesive to fasten on the outer canvas jacket. Glass fiber adhesive tape may be used on cellular glass. Any voids shall be pointed up with insulating cement.
O. D. Insulation sizes over 12"
Fasten the outer layer with stainless steel bands (5/8" x . 015). Spacing of bands shall be approximately 12" apart with no band more than 4" from an end joint. Any voids shall be pointed up with insulating cement.
Indoor Finish
On sizes under 12" O. D. cover with Osnaburg Rag using a lagging adhesive. O. D. insulation sizes over 12 inches shall always be finished with a weatherproof cover.
Weatherproof Cover
Apply Weatherproof Felt as shown on page 102 or an equivalent metal finish as shown on page 103.
Fittings
Use premolded fittings or fabricate as shown on pages 77 and 80.
STC0CO73?
page 70
INSTIGATION ON PIPE BENDS, < WELD ELLS, 4" AND LARGER,
AND MITER ELBOWS
1.0 APPLICATION PROCEDURE
1. 1 PIPE BENDS ALL SIZES:
Insulate bend with short mitered pieces of pipe insulation, same type as on adjacent pipe. Make pieces short enough to provide good continuous fit between pipe and insulation. Fasten pieces with copper clad wire or stainless steel bands.
1.2 WELD ELLS 4" & LARGER:
Insulate elbow with pipe insulation, same type as on adjacent pipe. Fasten with copper clad wire or stainless steel bands.
2.0 INDOOR FINISH
2. 1 BOTH TYPES:
Apply complete smooth coat hydraulic setting cement, 1/4" thick, working well into all seams and joints. Cover with Osnaburg Rag using a lagging adhesive.
!STQ0OO78J
pa^.p. 77.
3.0 WEATHERPROOF FINISH: 3. 1 PIPE BENDS:
Point all joints with hydraulic setting cement. Cover with strips of weatherproof felt cut to fit. Fasten with copper clad wire or staples as shown on page 55.
3.2 WELD ELLS:
Point all seams with hydraulic setting cement. Cover completely with 1/8" coat of asphalt mastic and while wet embed glass membrane fabric. Finish with 1/8" coat of asphalt mastic.
` 4. 0
INDOOR FINISH - ALL SIZES - MITER ELBOWS:
Insulate elbow with mitered pieces of pipe insulation, same type as on adjacent pipe. Fasten with 16 gauge copper clad wire or stainless steel bands.
Apply complete smooth coat of hydraulic setting cement 1/4" thick, working well into all seams and joints.' Cover with Osnaburg Rag, using a lagging adhesive.
5.0 WEATHERPROOF FINISH - MITER ELBOWS:
6" and Smaller: Point all seams with hydraulic setting cement. Cover completely with asphalt mastic.
8" and Larger:
Point all seams with hydraulic setting cement. Apply 1/8" coat of emulsion type asphalt mastic and while wet, embed glass membrane fabric. Finish with 1/8" complete coat of asphalt mastic.
Slngio layer application
(" ' C
ST0303782
page id.
MITERED SEGMENT DIMENSIONS
Short Radius Ells
PIPE SIZE
3 3ft 4 4ft S e ( 8 8 10 11 12 14 15 18 17 18 1920 21 22 C
24
R=D
N=No. of Segments
THICKNESS OF INSULATION
r
2" 2%" 3"
3% 18
4"
X u Y X N Y X NY X N Y X N Y X N Y X N Y
.
4% 3 % 4ft 3 %
3H 4 % 3ft 4 Yi
3% 4 % 3% 4 Y.
2% 6 3ft 8
ft 2% 6 %0
ft 3% 6 ft t 315 S 15 3% 6
ft
3% 6 3% 8 3ft 8
ft 3ft 6
ft 3ft 8
ft 35f. 8
ft 3ft 6 % 3ft 6 % 3% 8
ft 4 6 Y. 3ft 8 % 3% 8
ft 4ft 6 % 4ft 6 Y, 3% 8
ft
ft 4% 6 % 3ft 8
, ft ft 3% 8 Y.
3% 8 % 3ft 8 ft 3ft 8 ft 4 8 ft 4ft 8 ft 4% 8 Y, 4ft 8 ft
3% 8 1% 4
81
4ft 8 ft 4ft 8
ft 4ft 8 ft 4% 8 Y. 4ft 8 ft
4% 8 1% 4ft 8 ift 4% 8 1
4ft 6 ft 4ft 8 ft 4% 8 % 4% 8 H
4% 8 1% 4% 8 1% <% 8 1ft 4% a 1
4 8 ft 5% 8 % 5Y. 8 ft
4% 3 1ft 5
8 i% 5ft 8 1Y, Sft a 1% 5ft a
'Ki 5% 8 ft 5ft 8
%
SY 8 1% 5ft 8 1ft 5ft 8 ift 5V4 8 1ft Sft 8 1
5% 8 % Sft 8 ft
5% 8 1% Sft 8 1% 5ft 8 1% 5ft 8 1ft 6
6 ift 6% 8 1% 6ft 8 1
s% 8 1% 5ft 8 1% 6
8 ift 6ft 8 1ft 6ft' 8 1ft 6% 8 t*. 6ft 8 1ft
6ft 8 1% 6% 8 ift 6Y, 8 ift 6.Y. 8 1ft 6% 8 1ft 6ft 8 Itf. 6% C 1ft
6% 8 1% Oft 8 1% 6ft 8 1% 6ft 8 1% 6ft 8 1% 6%' 8 1% 7
8 1Y.
6% 8 1% 6ft 8 1ft 6ft 8 1ft 7
8 1H 7ft 8 1ft 7% 8 1% 7% 8 1ft ,,
7 8 2% 7Y. 8 2 7% 8 1ft m 8 1% 7% 8 1ft 7ft 8 i% 7% 8
m 8 2% 7H 8 2ft 7ft 8 2
7tt 8 1% 7ft 8 1ft 7% 8 i% VA'\ V Ji
Table 4-3
vmm
ST0000783
pa^,e /
C
MITERED SEGMENT DIMENSIONS
five Diancicr Pends
R=5D
of Segments
THICKNESS OF INSULATION
PIPE SIZE
r XNY
mX NY
2" VA"
3"
3%"
*r
X n" Y X N Y X N Y X N Y X N Y
9
2V< 12 2
2% 12 1% 2ft 12 1% 2'% 12 1>% 3
12 1ft 3ft 12 1ft 3ft 12 1ft
3ft 3ft 12 2% 3% 12 2ft 3ft 12 2% 3% 12 2ft 3ft 12 2% 3% 12 1% 3% 12 1'% 4 3% 12 2ft 3% 12 2% 3ft 12 2ft 3% 12 2% 3ft 12 2ft 3ft 12 2ft 3ft 12 2%
4% 3% 12 2ft 3% 12 2'% 4
12 2ft 4% 12 2%. 4ft 12 2ft 4ft 12 2ft 4ft 12 2ft
5
4% 12 3ft 4% 12 3% 4ft 12 3ft 4% 12 3% 4% 12 3
4ft 12 2ft 4ft 12 2ft
6 5% 12 3ft 5ft 12 3% 5% 12 3ft 5ft 12 3'% 5% 12 3% 5% 12 3% 5% 12 3n
6% 12 4ft 5ft 12 4% 5% 12 4ft 6
12 <% 6% 12 4ft 6% 12 4% 6% 12 4ft
8
6% 12 5ft 6ft 12 5% 6% 12 5
6ft 12 4>% 6% 12 4ft 6% 12 4ft 6'% 12 4ft
9 7ft 12 5ft 7% 12 5% 7ft 12 Sft 7% 12 5% 71i 12 5% 7% 12 5ft 7ft 12 5ft
10 8ft 12 6ft 8% 12 6% Sft 12 6ft 8% 12 6% Sft 12 6ft 8% 12 6% 8% 12 6
11
an 15 Sft 6% 15 5% 7
15 5% 7% 15 5% 7V 15 5ft 7% 15 5ft 7ft IS 554
12 7H 15 5ft 7% 15 5% 7ft 15 Sft 7% 15 5'% 7ft 15 514 7% 15 5ft 7ft 15 Sft
14 an 15 '6% 8% 15 6ft 8ft 15 6% 8% 15 6ft 8ft 15 6% 6ft 15 6% Cft 15 6%
15
8ft 15 6ft 8% 15 6% 8ft 15 6ft 8% IS 6% 9
15 6ft 9
IS 6ft 9
15 614
16 9ft 15 7ft 9'% 15 7% 9ft 15 7% 9% 15 7% S'i 15 7ft 9ft 15 7ft 9ft 15 7ft
17 9% 15 7% 9% 15 7'% 10 15 7ft 10% IS 7'% 10ft 15 7ft 10ft 15 7% 10ft 15 7ft
18 8% 16 6% Sft 18 6ft 8% 18 6% Sft 18 6ft 8% 18 6% 06/1^/4 18 6% 0% 18. 6%
19
8% 18 7% 8% 18 7
8% 18 6% 8'% 18 6ft 9
18 6% 9
18 6% 9
18 6%
20 9% 18 7% 9ft 18 7% 9% 18 7% Oft 18 7% 9% 10 7% 9% 18 7% 9% 18 7%
21
Sft
18 7% 9% 18
7ft
9ft
18 7% 9% .18 7ft
Sft
18 7%
Sft
18 7%
Sft
18
r=i 7%
22 10ft 18 Sft 10% 18 8% 10ft 18 8 10% 18 7% 10ft 10 7ft 10ft 18 7ft 1014. 18 7%C^
10% 18 6% 10ft 18 Sft 10% 18 8% 10ft 18 Sft 10'% 18 6% 10% 16 8% 10% 13;.
24 9% 22 7% 9ft 22 7% 9% 22 7% 9% 22 7W Sft 22 7ft 9% 22 714 OftV fcT m
*Pr>VO o ll
ll
;ST0000784
page 7^
INSULATING SCREWED AND WELDED VALVES AND FITTINGS
1.0 APPLICATION PROCEDURE 1.1 Butt the insulation tight to fitting or valve. Spot mineral wool cement to fitting or valve as shown above applying approximately same thickness as adjoining pipe insulation. 1.2 Indoor Finish - Overlay mineral wool cement with thin smooth layer of Hydraulic Setting cement extending it 3/8" over covering so as to make a tight joint. Cover with Osnaburg Rag using a lagging adhesive.
(Screwed Tees ore similar)
Pipe Insulotion Single or Double Layer
Butt Insulotion tight ogoinst fitting
Hydraulic Setting cement Mineral wool Cement
WELDING ELLS up to 4" (For 4* end lorger -See page 7C
<4
Hydraulic Setting cement Mlnoroi wool Cemont Pipe Insulotion
SCREWED VALVES thru 2*
Butt Insulotion . tight ogoinst volve
L;
Single or Double Loyer
-'-..I-.4- ' 4-
: WELP^tTf';'
1.3 Weatherproof Finish - Sizes 2" and smaller - Apply emulsion type asphalt mastic directly to mineral-wool cement. Sizes 2^" and larger - Cover mineral wool cement with thin smooth layer of Hydraulic Setting cement then apply asphalt mastic 1;" th.ck.
For Weld-end valves 4" and larger see page 85.
Note: Screwed unions usually are not insulated.
ST0309785
INSULATING FLANGED ELLS AND UNIONS, 1 LAYER
page 76
Finish -- Length of bolt plus 1"
Thickness of nut plus 1 Void-leave unfilled
Pipe insulation
Molded insulation
collar ^Mineral wool cement
Mineral wool cement
Same thickness as pipe insulation
(^'^/''"'Mineral
wool cement -
same thk'ness as
pipe insulation
Molded insulation collar
Hydraulic Setting cement
Sizes 6" & Smaller
Flanged Union
APPLICATION PROCEDURE
Flanged Ell
Block across flanges as shown above using same type of sectional insulation and thickness as on adjacent pipe. Fasten.with 11 ga. Monel wire.
Sizes 3" & Larger
Follow same procedure using block type insulation. Fasten with 5/3" stainless steel bands.
Cover bodies of flanged ells with mineral wool cement building up to same thickness as adjacent pipe insulation.
For bolt removal clearance, position pipe covering away from flanges the length of bolt plus 1" on the bolt side, and nut thickness plus 1" on nut side. (This does not apply to nut side of flanged ells) The void on the bolt side shall be filled with a collar made of the same pipe insulation plus mineral wool cement as shown in sketch.
Indoor Finish'
Sizes b" & Smaller
Overlay with smooth thin coat Hydraulic Setting cement. Cover with Osnaburg Rag using cold water paste.
Sizes 8" & Larger
Cover with Hydraulic Setting cement.
Weatherproof rFinish
Sizes b" & Smaller
Sizes'8" & Larger
Cover completely with K" asphalt mastic.
Cover completely with two 1/8" layers of asphait mastic with
glass membrane fabric between.
\
^Si-
L ST 0000787
insulating flanged ells
AND UNIONS, 2 LAYERS Finish Length of Bolt plus 1 -Thickness of Nut plus 1" Molded Insulation Collar
page 77
v>
r. i 4^
tL
IU.
Molded insulation collar
Void leave unfilled
Inner layer Outer layer Pipe insulation
Same thickness as pipe insulation
Mineral Wool cement Hydraulic Setting cement
APPLICATION PROCEDURE
Sizes 6" & Smaller
Sizes 8" & Larger
Block across flanges as shown using same type insulation and thick ness as on adjacent pipe. Use sectional type for inner layer and block type for outer. Fasten with 16 ga. copper clad wire.
Follow same procedure as above, using block type insulation. Fasten inner layer with wire or 5/8" stainless steel bands. Fasten outer layer with 5/8" stainless steel bands.
Cover flanged ell bodies with mineral wool cement, building up to same thickness as adjacent pipe covering.
To provide bolt removal clearance, position pipe insulation away from flanges the length of the bolt plus l" on the bolt side, and the nut thick ness plus l" on the nut side. (This does not apply to nut side of flanged ells.) The void on the bolt side shall be filled with a collar made of the same pipe insulation. See sketch.
Indoor Finish Sizes 6" & Overlay with smooth thin coat Hydraulic setting cement.
Smaller
Cover with Osnaburg Rag using cold water paste.
Sizes 8" & Cover with Larger
Hydraulic setting finish cement.
'*
-n.O
; S^O000783
page 78
C
Weatherproof Finish
Sizes 6" & Smaller
Sizes 8" & Larger
Cover completely with -j-" emulsion type asphalt mastic.
Cover completely with two 1/8" layers of asphalt mastic with glass membrane fabric between.
f
<C
c
LST0Q00789
page 79
INSULATING FLANGED VALVES, 1 LAYER
APPLICATION PROCEDURE
Sizes 6" & Smaller
Cover body as shown above using the same type of insulation as on adjacent pipe. Fasten with 16 ga. copper clad wire.
Sizes 8" & Larger
Cover body using block type insulation of same material as on adjacent pipe. Fasten with 5/8" steel bands.
For bolt removal clearance, position pipe covering away from flange the length of bolt plus 1" on bolt side. Fill void on bolt side with collar made of same insulation plus mineral wool cement as shown above.
Bonnets
Insulate all bonnets at temperature 350F. and above. Use block type insulation and mineral wool cement on sizes 4" and larger. Fasten with 16 ga. copper clad wire or 5/8" x . 015 stainless steel bands. On sizes less than 4", use only mineral wool cement applying same thickness as pipe insulation and overlaying it with smooth thin layer of Hydraulic setting cement.
Indoor Finish Sizes 6" & Overlay with thin smooth coat of Hydraulic setting cement
Smaller
and cover with Osnaburg Rag using cold water paste.
Sizes 8" & Larger
Weatherproof Sizes 4" &
Finish
Smaller
Sizes 6" & ! Larger
Cover with i" Hydraulic setting finish cement.
Cover completely with emulsion type asphalt mastic'%.^ :
- ....
Cover completely with asphalt mastic with glasamS
fabric between 1/8" layers of asphalt mastlc^^jC^w
fitted pieces of weatherproof fel^.and'wire-.^^^^,:'*
copper clad wire or stainlesS Steel'bVhds^p^m^?
with emulsion tvpe mastic.
................ *
iST0000790
page 80
INSULATING FLANGED VALVES, 2 LAYERS
I i
Sizes 6" & Smaller Sizes 8" & Larger Bonnets
Indoor Finish
Weatherproof ^''Finish
APPLICATION PROCEDURE
Block across flanges as shown above using same type insulation & thickness as on adjacent pipe. Fasten each layer with 16 ga. copper clad wire.
Follow same procedure using block type insulation. Fasten inner layer with 16 ga. copper clad wire or 5/8" stainless steel bands. Fasten outer layer with 5/8" x . 015 stainless steel bands.
Insulate all bonnets. On valves 4" and smaller, use mineral wool cement building up to same thickness as pipe covering. On valves 6" and larger, use block type insulation as shown, fastening with prescribed wire or bands. Fill bonnet void with mineral wool cement.
Sizes 6" & Overlay with thin smooth coat of Hydraulic setting finishing
Smaller
cement. Cover with Osnaburg Rag using cold water paste.
Sizes 8" & Cover bodies completely with
Larger
cement.
Hydraulic setting finish
Sizes 4" & Smaller
Sizes t" & Larger
Cover completely with asphalt mastic.
Cover completely with two 1/8" layers of asphalt mastic
with glass membrane fabric between, or cover with,f(tte`i
pieces of weatherproof felt and wire in place with coppl*
clad wire or stainless steel bands, properly flashed with
emulsion type mastic.
:'*i-'
[ST000079}
page 8l
INSULATING WELD END VALVES 21 & LARGER, 2 LAYERS
Sizes 2j" thru 4"
Sizes 6" & Larger Indoor Finish
Weatherproof Finish
Cover valve body with mineral wool cement building up to same thick- ness as adjacent pipe insulation.
Block across valve body as shown using same type insulation and thickness as outer layer. Extend it over pipe covering same distance as covering thickness. Fasten with 16 ga. copper clad wire.
Block across bonnet flanges as shown using double layer same as on adjacent pipe. Fasten with 16 ga. copper clad wire. Fill bonnet void with mineral wool cement.
Follow same procedure as above using block type insulation. Fasten inner layer with 16 ga. copper clad or 5/8" stainless steel bands. Fasten outer layer with 5/8" stainless steel bands.
Sizes 2j" thru 6"
General procedure. Cover body completely with thick Hydraulic setting finishing cement, and cover with Osnaburg Rag using cold water paste. Alternate: If a smooth finish is required, overlay the Hydraulic setting cement with thin smooth coat of asbestos cement. Cover with Osnaburg Rag using cold water paste.
Sizes 8" & Cover body completely with
Larger
cement.
Hydraulic setting finish
Sizes 4" & Cover completely with \" asphalt mastic. Smaller
-
QTn '
W I V.' v w
-07 I - <-
page 82
Sizes 6" Larger
Cover completely with two 1/8" layers of asphalt mastic with glass membrane fabric between, or cover with fitted pieces of Weatherproof felt and wire in place with copper clad wire or stainless steel bands, properly flashed with emulsion type mastic.
L ST0000793
APPLYING GLASS FIBER PIPE INSULATION
page 83
C
APPLICATION PROCEDURE
1. 0 Indoor:
1.1 On sizes below 12 inch, with canvas jacket use a lagging adhesive to fasten on the insulation. On sizes above 12 inch insulation O. D., wire on the Fiberglas with 16 gauge copper clad wire and band the jacket with stainless steel bands (5/8" x . 015).' Spacing of bands shall be approximately 12" apart with no band more than 4" from an end joint.
1. 2 With factory applied jackets such as FRJ the self sealing lap is sufficient to hold on the insulation. Staples should be used in cold weather to reinforce the self seal lap. Butt joint strips must be used with this system.
2.0 Weatherproof Cover
Apply Weatherproof Felt as shown on page m2 or an equivalent metal finish as shown on page 103 .
3.0 Fittings
3.1 Canvas finished lines: Finish as on page 74.
3.2 Factory applied jacket: Finish fittings 2" and smaller as on page 74, 2j" and larger as on page 76.
3.3 Weatherproof lines
a. Above 50F. pipe temperature insulate as on page 74.
b. Below 50F. pipe temperature miter covering at fittings, use larger sizes if necessary, cover insulation with two 1/8" layers of vapor barrier mastic with glass membrane fabric between.
(
.ST0000794
ppge 8^
TRACED SYSTEMS
C
Steam and Dowtherm Tracing
The installation of tracers on process lines, in addition to conduction, uses the principle of air convection in heat ing the annulus space between the pipe and the inside of the insulation. This system is sufficiently effective to be used where it is only necessary to maintain the pipe tempera ture at a considerable lower temperature than the steam inside the tracer. The use of spacers or asbestos sock is nocessar;when the temperature of the tracer line might cause degrada tion of either the process material or the pipe liner. In either case it is important to choose an insulation size large enough to fit loosely over both tracer and pipe lino. Piberglas will be used in most cases over traced lines. For the proper thickness see page 20. Application procedures for both insulation and weather proof jacketing can be found on page 85 and page 102
Heat Transfer Cement
When it is important to extract the maximum amount of heat from a tracer, heat transfer cements are employed. Two systems are used. One is by trowelling into position, com pletely covering the tracer and bonding it to the pipe. The cement should completely cover the tracer and extend out at the base on each side a distance equal to the diameter of the tracer. This much coverage is necessary to insure that the mechanical strength of the cement is sufficient to with stand the force exerted by the expansion of the tracer tubing. The other system is to install water-mix heat transfer cenent with metal channels. These channels may be factory filled or they may be filled at the time of application. The filled channels are pressed over the tracer >-.nd secured in place by stainless steel bands.
This latter method is used with electrical tracing and special care must be exercised to insure that there are no voids. Should parts of electric tracers not be thermally connected with heat transfer cement these spots cannot trans fer the heat generated to the process pipe. In turn this will cause a temperature rise at this spot resulting in a burn-out. A special flexible cover should be used where a flange or elbow occurs in the line. Proper use of the channels is shown in the sketches on page`86 . Amounts of cement needed to cover tracers are shown in the table on page 87 . Because of their large outside area as compared to pipe, valves require additional tracer length and very careful installation of the heat transfer cement.
C
[ST0000795-
page 85
All surfaces, on which heat transfer cement is to be applied, must be cleaned to the bare metal. All rust, dirt and oil should be removed. The entire surface of
valves, pumps and other pieces of equipment must be thoroughly cleaned. It is imperative that a good bond be formed between the metal and the cement. Without this bond considerable heat transfer efficiency is lost.
C
C
LST003079/
page 87
CEMENT COVERAGE PER SINGLE PARALLEL TRACER WATER-MIXED HEAT TRANSFER CEMENT
TRACER SIZE 1/4 OD 3/16 OD 3/8 OD 1/2 OD 5/8 OD
3/8 OD 1/2 OD 5/8 OD 3/4 OD
TROWELLED ON PROCESS LINE SIZE
1/2" through Flat 1/2" through Flat 1/2" through 1-1/4" 1-1/2" through Flat 1/2" through 1-1/4" 1-1/2" through Flat 1/2" through 1-1/4" 1-1/2" through Flat
FEET OF TRACER PER GALLON
50 49 45 48 30 33 23 28
IN METAL CHANNELS
1/2" through 2" 2-1/2" through Flat 1-1/2" through 2" 2-1/2" through Flat 1-1/2" through 2" 2-1/2" through 2-1/2" 4" through Flat
37 to 41 34 to 37 43 to 47 40 to 43
44 to 48 39 to 32 28 to 30
TABLE 4-5
"i'ST00G0798
page 88
EXPANSION JOINTS
High Temperature Piping
Rigid insulation applied to high temperature piping may be single or double layer, depending upon the service conditions and temperature. When there are long runs of piping, and where the piping is large, the problem of expansion occurs again. To make the problem more troublesome, most high temperature insulations shrink as they are subjected to higher tempera tures.
The circumferential expansion of pipe within the covering does not present a problem as the covering is manufactured with an inside diameter greater than the O. D. of the pipe. High temperature pipe covering should not fit snugly on the pipe at atmospheric temperature, but should have sufficient clearance to allow for expansion of the pipe. Properly installed, the insulation should be free to slip on the pipe without binding, even after the line is in service.
Single layer pipe insulation should be installed with staggered joints, and multiple layer insulation should be installed with staggered broken joints. This secured cylinder of insulation should be free to slip as the pipe expands and insulation itself shrinks. Of course, this requires that, at the correct distances, one insulation cylinder be separated from the adjacent cylinder by an expansion joint. This is to prevent the frictional pull exerted by expansion of the pipe from pulling the insulation assembly apart. This can be accomplished by an expansion joint, or by using a flanged insulation cover as an expansion joint.
Not every straight run of pipe needs an expansion joint. The need must be determined by the length of the pipe, its temperature, metal of pipe and shrinkage of the insulation.
A typical expansion joint, and an expansion joint using a flanged insulation cover are shown on page 76,
For differential expansion between foamglas and metal piping, see page 91 .
For differential expansion between Dow ceramic foam and metal piping, see page 9Z
C
S 7 n n t\ -'*700
TYPICAL JOIMTS
LENGTH OF PIPE OR VESSEL AT ATMOSPHERIC TEMPERATURE
RIGID INSULATION
FLEXIBLE 'INSULATION
I
V JOIMT COMPRESSES LENGTH OF PIPE OR VESSEL AT LOW TEMPERATURE
CONTRACTION JOIMT FOR LOW TEMPERATURE
LENGTH OF PIPE OR VESSEL AT ATMOSPHERIC TEMPERATURE
RIGID ^--INSULATION--y
FLEXIBLE --INSULATION
(COMPRESSED)
,,
ill
I /AA
> c
\ jA\
1i --
JOINT EXPANDS----- f
LENGTH OF PIPE OR VESSEL AT HIGH TEMPERATURE
EXPANSION JOINT FOR. HIGH TEMPERATURE
*
C C
ST0000330
page 90
TYPICAL. EXPANSION JOINTS
5UP JOINT INSULATION STRAP
PACK TIGHTLY WITH FIBROUS INSULATION
WEATHER-BARRIER SEAL OVER SLEEVE'
PQ
m &
i
mtimiumiwtn RIGID PIPE _V INSULATION WEATHER BARRIER-
IT
wrnmm
STAIK1LESS STEEL SLEEVES O.OtO"THK.
55 A
( to EXPAMSIOM JO)MTS IM STRAIGHT PIPES
PREFORMED FLANGECOVER
FLANGE COVER SECURED TIGHTLY OKI THIS SIDE
Ilf
INNER RADIUS OF FLANGE COVER SLIGHTLY OVERSITE SO AS NOT TO BIND ON PIPE INSULATION
INSULATION STRAP
.weather-barrier SEAL OVER SLEEVE
iPffr HJLT
RIGID PIPE
STAINLESS STEEL
INSULATION
SLEEVES 0.010*: THK.
c WEATHER-BARRIER.-
SLIP JOINT
HEAVY FILLET OF CAULKIN'
EXPAMSIONJ JOIMT AT fI^AMSE*
'1ST000080 f
page 91
. DIFFERENTIAL EXPA AA5/QAJ ~:\BTWES> POAMCLAS AMD MTA L PIPING
C
c
NO TP : ' TPERNA L EXPANG/ON OF P/PE CALCULATED . FROM 30 F TO OPERA T/NC rCNPEPATUf($.
ZFOAMgLas XPAM5/0/j CALCULATEDM
50< -------------------
''
------------------------- '
""
1./
IST0000802
D/FFERE/JT/AL EXPAUS /ON GETWEEN OOW CERAM/C FOAM AH0_METAL .P/P/Mp-
A/O T : THERMA L ZXPAAJS/ON OF P/PE CALCULATES FROM 60 TO OPERA T/AJQ TEMPERATURE. DOW CERAMfC FOAM EXP AMS/ON CALC(/lATEQ FROM <3O' F 70 MEAM TEMPERATURE OF /RSULAT/OM.
u STOOD08.Q3
APPLYING STYROFOAM ON PIPE
page 95
c
1.0 2.0 3.0
Sectional Form
Segmental Form
Indoor Finish
Position half sections on pipe so that all end joints are staggered approximately 18" apart and the longitudinal joints are on top and bottom of pipe. Coat faces of all joints with waterproof adhesive cement, coating only one face of adjoining surfaces. Do not cement Styrofoam to pipe. Fasten half sections together with 3/4" Filament tape, wrapping tape twice around covering. Place tape each side of all end joints. Space intermediate tape about 8" apart. All tape shall be straight and tightly wrapped.
Position segmental blocks so that end joints are staggered relative to each other. Start with~18" and 36" pieces placed alternately around pipe. Cement all joints following same procedure given for sectional form. Fasten segments together using 5'8" x .015" Stainless Steel bands. Position one band each side of all end joints and space intermediate bands 6" apart.
Sectional Form
Segmental Form
1. Paint as per Dow Painting Spec., or
2. Cover with 26 Ga. galv. sheet metal where physical protection is required,
(when specified)
on page 102
1. Cover with Weatherproof Felt following procedure
but, instead of
staples, fasten with No. l6Ga.
wire loops, spaced on 4" centers, or
2. Cover with 26 Ga. galv. sheet Metal, (when specified)
3. Cover with 1/4" Hydraulic Setting finish cement, (when specified)
4.0 Weatherproof Finish
Both Forms
Cover with Weatherproof Felt, same as above. In corrosive areas, all laps shall be glued and sealed with waterproof lap cement.
i
page 94ST00Q0804
c APPLYING STYROFOAM ON ELBOWS
Indoor Finish
Weatherproof Finish
APPLICATION PROCEDURE
Cover bend with short mitered pieces of Styrofoam. Cut pieces short enough at correct miter to give good continuous contact between pipe and Styrofoam. Work from each end of bend making last piece a full tight fit.
Use waterproof adhesive cement on all joints coating one face only of adjoining surfaces. Do not cement Styrofoam to pipe. Fasten pieces separately with 3/4" Filament tape wrapping around twice on each loop. All joints shall be made absolutely tight. Pipe bend applications shall not be allowed to stand unfinished.
Paint as per Dow Painting Specifications
1. Cover with V/eatherproof Felt following procedure on p 102 but, instead of staples
fasten with No.16 Ga.
wire using as many loops as required to give snug fit.
In corrosive areas glue all laps with waterproof lap cement, or
2. Cover completely with two 1/3" layers of asphalt mastic with glass membrane between. (When specified)
c
ST0000805
APPLYING STYROFOAJ^ ON ELLS AND TEES
page 95
c
c
SCREWED ELL
Screwed Ell
General
Indoor and WeaUierproof Finish
Lay out dimensions A and B on both half sections so that Line D is at 45. Groove on* Styrofoam to snugly fit ell. To correctly assemble, butt the cut ends of pieces 1 and 3 together on one side of ell. (Fig. 2)., and pieces 2 and 4 on opposite side, (Fig. 3). Cement joints as specified below. Tape together as shown in Fig. 3.
Cement all joints with waterproof adhesive cement, coating only one face of adjoining
surfaces. Do not cement Styrofoam to fitting. Butt the joints tightly together. Fasten
with 3/4" Filament tape wrapped tightly around and using two loops, or fasten with
5/8" x .015" Stainless Steel bands. All loops and bands shall be drawn straight and
tight. All joints shall be made absolutely tight. ,
( -F --
? . .. j
Completely cover with two 1/8" 1 Alternate, If specified: Cover with
1 ......... . L `
*'*
i S.TOO00806
page 96
.APPLYING STYROFOAM ON VALVES
Valve Body
Valve Bonnet Voids General
Indoor and . Weatherproof ' Finish
APPLICATION PROCEDURE Field Fabrication
Cover body by blocking across pipe covering as shown in sketch using same Styrofoam thickness as on adjacent pipe. Use sectional or segmental block form depending on O.D. of adjacent covering. Fill in bolt removal area v/ith Styrofoam collar to fit. See above.
Insulate bonnet to a point level with stuffing box using sectional or segmental form of required thickness. Leave stuffing box free~ahd accessible for adjustment and packing.
Voids shall be completely filled with a mixture of granulated Styrofoam, Type Grind A, and melted paraffin.
Cement all joints with waterproof adhesive cement, coating only one face of adjoining surfaces. Fasten sectional covering with 3/4" Filament tape wrapped around twice on each loop. Fasten segmental blocks with 5/8" x .015" Stainless Steel bands. All loops and bands shall be drawn straight and tight.- All joints shall be made absolutely tight.*
Cover completely with two 1/8" layers of asphalt mastic with between.
iST000080?
page 97
STYROFOAt^ CUTTING DIMENSIONS, MITER BENDS
B * (2R-D) TAN 224*
A " B (2R -D)
E = 2R TAM 224* 0 0.0. OF COVERING
r - (*'B)
LIGHT DUTY PIPE SI2E
3
STANDARD DUTY
PIPE SIZE
3
4 4
6 6
8 8
10 12
--
10
12
HEAVY DUTY PIPE SIZE
0 0,0, of COVERING
6-75 8.87
3 9.62 7.87
9.62
4 11.12 10.25
12.19 6 14.62
12.19
14.62 8 16.25
14.62 17.37
10 19.12 16.25 19.12
12 21.00
R
7% 7% 7*4 9 9 9 11% II% 11% 14 14 14 I6Vj 16V*
16V? 19 19 19
Table 4 -6.'
Alt dimensions ere In Inche-s
ABE F
9*4s 10 Vo
3% 2%
10% 2% 10% 4%
II Vo
l2vo 13%
14*0
2V/j? 5% 4%
15% 16%
3U% 6%
17% 5*%l 18% 4%
I9/u 20%
7% 6^6?
21% . 22%
5V
9
23%
' 7/o
24% J r7%
6% 2TMV 6% 3%i 6% 3/j, 7% 3% 7% 4
7% 4% 9% 4%
9V* 5% 9% 6% II % 5%
11% 6% 11% 6U%
13% 6%? 13% ~?"
13% ?v-
15% - ~6*%
15% : 15%
1*7,,k. ,i;f a.:
>*
STCO00808 page 98
r B = (2R-D) TAH ID*
A
*B
(221R
((221R
-
D)
D)
E c 2R TAN 15* D = O.O, OF COVERING
F = MI
UIGHT K DOTY
71PE SIZE 3
4
6
8
10
12
STANDARO DUTY
PIPE SIZE 3 -- 4
_6
8
10
12
HEAVY DUTY PIPE SIZE
3 4
6
8
10
12
0 0.0. Of COVERING
6.75 8.87
9.62 7.87
9.62 11.12 10.25
12.19 14.62 12.19
14.62 16.25
14.62 17.37
19.12 16.25 19.12 21.00
R
73/, 7*/, 73/, 9 9 9 11*6 II1': 111'? 14 14 14
16 I6`/* I61'* 19 19 19
All dimensions are In Inches
A8E F
531/jj 6 ' 6>/
6IJ/11 7W/J2 7"/u
8*/,, 9*6* ioj6i l03/ 1 11J<rJ7 1 l7/a I2*Vji
13^37 U`V32 I5*6 15^1*
2/ l'37
lw'3* 2/ 2*/,
l"/j7
3'37 2W/,, 2*/, 4Vf
3`9/>7
3**7 4lS/ 434* 3'S7 5*737
56i
4*67 |M/U
4*62
2*/,
4*67 2l*/,,
4 /u 4/
2`/| 2`Vj,
iwr " 2*Vj2
6*67 23/,
6*67 '3*61
6*67
3^37
7/ 3/
7Vl 3**/>7 7/ A`V
e^/ji 3*V,2
8r/37 er/37 103/tt 10*64
4*/j7 5^8 4`V,,
5*7*
lo*6s
5*/o.,
u.STD00;0809
page 99
FOAMGLAS INSULATION (PIPING INSTALLATION)
1.0 fastenings Stainless Steel Strapping or Bands Fiberglas Filament Tape Nylon Bands DO NOT USE WIRE OR STAPLES
2.0 Finish Mastic Black and White Armored Felt Tufjac
3.0 Application on Fittings (Valves, Flanges, etc.) 3.1 Avoid use of small mitered pieces. Instead purchase factory prefabricated fitting covers.
I
c
i
;to:oo8 ! o page 100
C
Foamglas Insulation (Cont'd.)
3.0 (Cont'd.)
3.2 Specify If fitting covers are to be removable.
(Removable covers can show cost savings after repeated removals for maintenance In that they are reusable)
4.0 Special Applications
4.1 Steam traced pipe lines.
4.2 For prevention of auto-ignition, see page 101
This detail
is for long uninterupted (by fittings)
runs where material cost savings from using a less expensive
insulation
can be recognized.
C)
o
ST 0 0 C 081 (
FOAMGLAS INSULATION
page 101
2. Foamglas pipe insulation
3. Calcium Silicate (or other insulation)
4. Stop ring, designed to stop the flat of any leakage to the Calcium Silicate insulation. Ring should be approximately 1/2 of the insulation thickness above the pipe.
STOP RING DETAILS
Detail "A"
/CONT.
,
r~
U_--. --'
WELD
Detail "B" S- CAULK
Detail "A" Ring - 16 ga. steel plate, continuous weld.
Detail "B" Ring - Sheet metal split ring banded in place with stainless steel band. Caulk with Dow Corning high temperature (Black) Sealant RTV-732.
Detail "B" is primarily for use in no welding areas.
crnAppAio W V w V* O I 6
page 102
WEATHERPROOF FELT JACKET
c Lap for O.D. up to 2" Lap over 17" O.P.
APPLICATION PROCEDURE
1.0 O. D. Insulation Sizes up to 24"
2.0 O. D. Insulation Sizes over 24"
3. 0 Fittings
4.0 Pre-Cut Felt
Pull weatherproof felt up tight against insulation, white side out. Lap the felt as shown so that the joint will shed water. Conceal longitudinal laps as much as possible. Entire length of lap shall be stapled approximately every 2 inches using either a hand or power stapler and | inch Outward Clinch Monel staples. See page 55-.
In addition to the monel staples stainless steel bands (5/8" x . 015) shall be used. Spacing of bands shall be approximately 12" apart with no band more than 4" from an end joint.
Pipe bends: Finish as on page 71. Flanges: Cover with weatherproof felt and staples. Sizes ' ' over 12" O. D. insulation size shall be banded with stainless steel bands (5/8" x . 0151 or wired with 16 ga. Copper Clad wire in addition to stapling. Valves: Large valves may be finished with weatherproof felt in the same manner as with flanges. All end joints shall be filled with an emulsion type mastic.
Pre-cut and prerolled weatherproof felt with a self sealing lap is available in various sizes. See page 56.
ST00008I3
METAL JACKETS
page icvj
1.0 Types 2.0 Fasteners
3.0 Fittings
APPLICATION PROCEDURE
1.1 Pre-cut and pre-rolled with locking (Pittsburgh) joint and matching butt joint sealer strips.
1.2 Rolls 36" wide by 100 feet. Cut rolled and applied in the field.
Locking joint type should be fastened at each butt joint with plated sheet metal screws through the sealer strip. Plain roll type should be lapped 1" on the lateral seam and 2" at the butt joint so they will shed water. Plated metal screws or pop rivets spaced on 9" centers are used to secure the jacketing. Flashing mastic should be used around projecting nozzles and supports to provide a weatherproof finish.
Flanges and valves may be covered with metal in much the same manner as with weatherproof felt. All end joints should be covered with an emulsion type mastic.
C
.7EATHERPR00F FELT OR SHEET METAL COVERING CHART
WIDTH Of WEATHERPROOF FELT OR SHEET HETAL REO'D
0p? INSULATION thickness inches
size
Jflcn
1
4
1
wr '? 2 H 3 4 Std Std.
i 8 10 13 16 20 24 29 9 16 9 II 14 17 21 24 31 10 l$
i 10 12 IS 19 22 25 31 II 10 >i II 13 16 20 23 26 33 12 19 li 12 13 18 21 24 27 33 13 20 2 13 IS 19 22 25 20 35 15 24
2i IS IS 21 24 27 29 35 17 25 3 18 T9 22 2S 8 32 33 19 29 4 21 22 25 29 32 35 41 23 30 5 24 25 29 32 35 33 45 ZT 34 6 23 29 32 35 39 42 43 30 37 8 34 3S 39 22 45 43 54 37 45
10 41 42 45 23 52 55 61 44 52
12 47 23 52 55 50 61 67 52 61
14 51 52 55 53 62 65 71 55 65 16 57 59 62 65 60 71 73 62 72 18 63 65 63 71 74 70 84 68 78
20 70 71 74 78 81 81 93 74 84
22 77 78 81 e4 87 90 95 81 90 24 82 04 07 90 93 S3 103 07 S3 2S 89 90 93 96 S3 103 IC9 93 103
28 94 9S too 103 ICS 109 115 ICO ICO
30 101 ICO ICS 109 112 II5 122 106 115
HO.ROLLS tE ATHEPSROOF FELT REO'D PER IOO LINEAR FT.PIPE
INSULATION THICKNESS INCHES
Size
'LrJr--h
i
4
3 0.7
1 OS 1.2
2 2s 1.4 I.C
3 4 Std. * >1 1 2.t 2.6 0.0
i 0.0 I.C 1.2 1.5 1.9 2.1 2.0 1.0 1.4
i 0.9 l.l 1.3 1.7 2.0 2.2 2.0 l.p 1.6
ii 1.0 1.2 1.4 1.0 2.1 2.3 2.9 l.l 1.7
l.l 1.2 1.6 1.9 2.1 2.42S 1.2 I.C
2 1.2 1.3 1.7 2.0 2.2 2.5 3.1 1.3 2.1
2} 1.3 1.4 1.9 2.1 2.4 2.7 3.2 I.S 2.2 3 1.6 1.7 12.0 2.3 2.0 2.C 3.4 1.7 2.6
4 1.9 2.C 2.0 2.6 2.C 3.1 3.7 2.0 2.7 5 2.1 2.3 2.6 2.0 3.1 3.4 4.0 2.4 3.0; 6 2.5 2.C 2.8 3.2 3.5 3.5 4.3 2.7 J'-| 0 3.0 3.zi3.5 3.7 4.0 4.1 4.8 3.3 4.0\
| 10 3.6 3.7\4.0 4.3 4.6 4S S.4 3.9 4.c 12 4.2 4.5 4.6 4.9 5.2 S.2- 6.0 4.6 5.4
14 4.5 4.C 5.0 5.2 5.4 5.C.6.3 5.0 5.0
15 5.1 5.2 5.5 5.8 6.2 6.3 6.9 5.5 6.4
10 5.6 5.6 6.0 6.3 6.4 6. 7.5 6.0 Cr.81
20 6.2 6.36.6 6S 7.i
8.0 6.C 7.5
22 6.8 e.i 7.2 7.5 7.7 0.6 8.5 7.2 0.0
24 7.3 7.517.7 8.0 8.3 8.5 9.2 7.7 0.5
26 7.9 8.C 0.3 8.5 o.c 9.2 9.7 8.3 9.2
20 8.4 8.5 C.9 9.2 9.4 9.7 0.2 8.9 9.7 30 9.0 9.2 9.4 9.7 10.0 10.2 `0.9 8.4 10.2
i___
NOTE: Based on 1" longitudinal lap for Insulated O.D's 17" & smaller & 2" lap for larger than 17", All end laps shall be 2",
NOTE: Based on 103 sq. ft. rolls.
)
ST00008I5
WALL AND FLOOR SLEEVE SIZES
page 105
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ST0C:03'6
page 106
WEIGHT OF PIPE INSULATIONS FOR PIPE SIZES 12" OR LESS
W / G U T O F P / f > I k l S U L A T t O M S . - L & S i e & G C t M Z A G FOOr.
ST00008I7
WEIGHT OF PIPE INSULATIONS FOR PIPE SIZES 14" OR GREATER
page 107
' WEIGHT OF PIPE INSULATIONS POUNDS PER LINEAR FOOT-
PE S IZ E
o rO 'S CO CM *3
CM
r~ iri
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if)
o CO
id rO
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m id
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,ST00008I 8
page 108
C CAREYTEMP 1500
APPLICATION OF BLOCK & SEGMENT INSULATION
Sidewall surfaces over 24" diameter up to and including 60" diameter shall normally be insulated with CAREYTEMP 1500 curved segments. See table on page 109. Surfaces over 60" diameter shall be insulated with Careytemp 1500 flat blocks. This material shall be securely fastened with 16 gauge monel or copperweld wire or .015" x 5/8" stainless steel bands on 12" to 18" centers using staggered joint construction.
All voids and joints shall be pointed up with Insulating Cement. Then apply wire mesh over the insulated surface. Finally, apply a 3/8" to 1/2" coat of Insulating Cement over the wire mesh. If Careytemp Cement is used, it shall be applied in two coats with the second layer troweled smooth.
Indoor work shall have a final 6 or 8 oz. canvas (muslin) jacket neatly pasted in place over the insulated surfaces.
Outdoor application shall be weatherproofed by either applying a 1/4" (1/8" dry) thickness of emulsion type mastic reinforced with 1" wire mesh, or a suitable jacket.
It is recomnended for large vessels such as towers, tanks, stills, etc., that
C angle iron supports be installed on 12 ft. centers. (See page 147) On large vessels, vertical angle iron members should be installed to hold a 30 ft. maximum length of the securing wire or band. Horizontal vessels over 6 feet in diameter should have two steel angles welded to the vessel shell approx imately 30 degrees below the horizontal center line. The depth of these supports should be held to 1/2" less than the insulation thickness.
Vessel heads can be covered by one of several methods. Dished heads 18" and smaller, and equipment of irregular shape, may be insulated with mineral wool cement up to the required thickness. Larger heads can be covered with flat blocks in the conventional manner.
The use of square double curved beveled blocks is one of the new developments and should be taken advantage of whenever possible. A grinding technique has been developed whereby square blocks of Careytemp, Foamglas, Styrofoam or Urethane foam insulation can be cut with a curved surface to fit any desired head radius. See figure on page 110. These curved blocks will give an effective insulation job without the need to fill a large number of voids. In most cases the radius of a bumped head will equal the diameter of the tank.
The blocks must be ordered from our DVS vendor, thus a lead time must be allowed. When ordering blocks the following information is necessary:
a. Square feet of surface
b. Required thickness
c. Radius of the curved head
ST0000819
page 109
CAREYTEMP 1500 CURVED BLOCK CHART
Vessel Diameter
14" 16" 18" 20" 22" 24" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46"
Width of Block
6" 6" 6" 6" 6" 6" 12" 12" 12" 12" 12" 12" 12" 12" 12" 12" 12"
No. of Blocks
10 11 12 13 14 15 8 8* 9 H 10 10| ni 12 12 13 13
Pipe Size of Curved Block
16" 16" 16" 26" 26" 26" 26" 26" 32" 32" 32" 32" 42" 42" 42" 42" 42"
1. Cut bevels so opening, if any, will be on outside and can be filled in with cement.
2. Available thickness - ljr" & 2"
3. All blocks are 36" long.
4. Specify total number of blocks, thickness (l" or 2"), width of each block (6" or 12"), and pipe, size of blockrequired.
. 5. For diameters over 46", use 6" wide x 36!'.long.flatJjlocksfj
..v Table 5-1
! S TO 000820
page 110
PRE-CUT VESSEL HEAD BLOCK
APPLICATION Pre-cut curved beveled blocks are Installed similar to floor tile. Starting at the center blocks are laid in a straight line in one .direction. Install a second row 90 from the first row. The space between the rows is then installed starting at the apex. Cut the head blocks to fit inside the body block and bevel as shown. Blocks may be cut from Careytemp, Cellular Glass Foam, Styrofoam or Polyurethane Foam.
ST 0000821
PREFORMED PUMP COVERS
page 111
C
1.0 Scope
Two piece prefabricated pump covers are available for standard size Goulds and Durco pumps. Covers for other makes of centrifugal pumps can be fabricated from a drawing or pattern. These covers can offer appreciable savings in applications where the cover must be removed at frequent intervals.
The covers are designed to be fastened together with stainless steel bands and have adequate room inside to handle tracing.
2.0 Material
The covers can be fabricated from any rigid type of insulation such as Careytemp, Foamglas, Styrofoam or Polyurethane. Thicknesses are optional from 3/4 inch to 2 inches. Outside finishes are available in any of the standard mastics such as Thermotex, Vinylacrylic, Hypalon or Epoxy.
'.ST0000822 page 112
3.0 Sizes available Patterns have been made up for Goulds and Durco pumps in impeller sizes 6, 8, 10 and 13 inches. Inlet and discharge pipe sizes should be specified.
4.0 Ordering Information The covers should be ordered by requisition from Industrial Insulation, Inc., Bay City, Michigan. Specify as follows: 1. - Pump size 2. - Inlet and discharge pipe size 3. - Material required 4. - Thickness required 5;--- Finish desired
ST0000823
page 115
VESSEL INSULATION, 46" O.D. AND SMALLER
C
APPLICATION
.0 HEADS
Use block insulation, fasten with 5/8" x .015" stainless steel bands or copper wire. Point up and fill voids with hydraulic setting cement. For alternate on small dished heads 18" O.D. and less, mineral wool cement may be used.
.0 BODY
>.0 INDOOR FINISH
Up to 14" O.D. - Use pipe size insulation. 14" to 46" O.D. - Use curved block insulation. See pg. 109. Fasten with metal bands. Point up and fill voids with insulating cement.
Heads - Cover with insulating finishing cement 3/8" minimum thickness.
Body - Cover with Protective Jacketing.
Alternate, when specified: Finish with insulating finishing cement same as for heads.
.0 WEATHERPROOF FINISH
4.1 Heads - Apply two 1/8" layers of asphalt mastic emulsion
or other suitable masticB with glass membrane fabric between layers.
:'I:?t VL)
^'-ij
Flashing - Seal around projecting nozzles, suppox
etc., with Vaporseal mastic and " membrane fabric. . See page 4.2 Body - Same as for heads.
4;
C
-
o 1 ^ f\ rs r\ |
---------c2 4 page 114
4.3 - Alternate finishes for body, when specified: A. Protective Jacketing - See page 57 Plashing - Seal around projecting nozzles, supports, etc., with Vaporseal mastic rein forced with glass membrane fabric. B. Weatherproof felt: lap 2" minimum and fasten with staples on 2fi centers, or use stainless steel bands. Plashing - Seal around projecting nozzles, supports, etc., with vaporseal mastic rein forced with glass membrane fabric. See pg. 151. For alternate method with flanges not in sulated, see page 115.
't, ;
ST0000825
page 115
5.0 Method for Insulating Heat Exchangers with Flanges Left Bare,
Use Mineral Wool Cement. If outdoors, weatheroroof with vaDorsea! mastic and glass membrane fabric See page 151
Blanket insulation cut to fit and pressed into guard halves or block insulation cemented into guard with mineral vrool cement.
. C+2T .
Bolt
: length
! plus f
? Bolt length
1--
w
1
DETAIL A Bevel Detail at Flanges
--I- Allow
clearance for bolt removal
DETAIL B
Insulated Split Guard for Flange Joints Make from No. 22 Ga. Galv. Steel with corners locked and soldered outside. Note: Apply weatherproof finish to body (if outdoors) before installing guard
Seal with Mineral Y/ool
Cenxintand
Vn/'v r S'.'J
Muitie if outdoors.-
rovide Lifting lug
rnn
Bevel insulation to permit boit removal
s" Detail "A'-*-
vfTi r rr-y///
For Application Details and Finish - See page 113.
Note: This method may be used for low temperature heated equipment or for vessels which require' frequent opening for cleaning and/or repairs. If personnel protection is required, use Insulated splil gCiari^^
ST000082SpaEe 116
Block insulation-
Flash around nozzles& projections similar
to page 151
Insulate nozzles as a pan of piping
Detail *A' below-
BLOCK INSULATION ON COLUMNS,
46" O.D. AND SMALLER
copper
5/8' x .015 Stainless steel hands or
wire *
-Finish - see below
m
. Point up all voids with insulating cement Tie ring as on pages 146 or 148.
"~-i~i *
f
Hydraulic setting cement. Finish same as top head protective jacketing -
IV/-U =:i j
<
Tie and support ring ahove each flange
Insulate manholes if over 4Q0F or for safety
Do not Insulate skirt insulation Sheet metal Drip edge
Mineral
wool cement finish
j
DETAIL "A'
Support rings reouired if fiances are more than 15^ apart.
Pipe size insulation up to 30' O.D. curved blocks 32' to 48' O.D. Fasten with stainless steel bands. Point up joints and fill all voids with hydraulic setting cement. Alternate finish when specified. Apply two 1/8" layers of asphalt mastic with glass membrane fabric between layers. Seal around nozzles, flanges, supports, etc. Block around flanges if over 400F or for safety.
Insulate bottom head with flat block. Cement on with asbestos-silicate mixture. Weld nuts or hair pin wires to inside of skirt and tie blocks with No. 16 gauge Monel v/irc. Cover with !' hydraulic setting insulating cement. Support ring
FINISH ON TOP HEAD
INDOOR WEATHERPROOF
Cover with hydraulic setting insulating cement 3/8' minimum thickness.
Apply 1/8' minimum thickness of asphalt mastic while wet, "
imbed glass membrane fabric and follow with 1/8' final .^a-aSjrC j|
layer of asphalt mastic. ,
. ^:v.
STQ000827
pap;e 117
BLOCK INSULATION ON HORIZONTAL TANKS, 48" O.D. AND LARGER
BODY & HEADS INDOOR FINISH
WEATHERPROOF FINISH
MECHANICAL INJURY
APPLICATION
Use__ black insulation or douole layer, as required. Band heads as indicated on pagel45Point up joints and fill voids with hydraulic setting cement.
Heads - Apply l'liex mesh galvanized v/ire netting and cover with hydraulic setting insulating cement 3/8* minimum thickness.
Body - Protective Jacketing - See p&g 57
1. Alternate - when specified. Weatherproof felt with 2" hps in eact: direction.
'Faster, with
staples
on 2"centers.
Heads - Cover with two 1/8" layers of asphalt mastic with nlass faoric between layers.
Body - Protective Jacketing -
ALTERNATES WHEN SPECIFIED. 1. Weatherproof felt as per (1.) aoove. 2. Cover with two 1/8' l.-yers of asphalt
mastic with glass faerie between layers.
Flashing - Seal around projecting nozzles, supports, etc., with flashing mastic l=j and glass fabric. .
Where vessel may be subject to severe mechaniical injury, apply j/8" layer of hydraulic setting insulating cement over the insulaattiioonn,, and finish'body- with protective jacketing
ST0000828
BLOCK INSULATION ON VERTICAL VESSELS, 48" TO 1210" O.D.
page US
80DY& HEADS INDOOR FINISH
CORROSIVE AREAS WEATHERPROOF FINISH
c
MECHANICAL
INJURY'
Use flat block insulation, single or double layer as required. Stainless steel band heads as indicated. Point up joints and fill voids with hydraulic setting cement.
Heads - Apply 1" hex mesh galvanized wire nettinq and cover with hydraulic settha insulating cement 3/8" minimum thickness.
Body - Protective Jacketing - See page 57
1. Alternate when specified: Weatherproof felt with 2" laps in each direction.
Fasten with
staples
on2'' centers.
Use weatherproof finish as per alternate (2) below.
Heads - Cover with two 1/8" layers of asphalt mastic with glass fabric between layers.
Body * Protective Jacketing - See
. Alternates when specified: 1. Weatherproof felt as per (1J above. 2. Cover with two 1/8" layers of asphalt mastic Wltih glass fa$
Where vessels may be subjects to severe mechanfcaj 1
hydraulic setting insulating cement overjhe.lnsula Protective Jacketing -\
'
ST 0000829
BLANKET INSULATION ON HORIZONTAL VESSELS, 48" O.D. AND LARGER
page llf>
0 HEAOS BODY INDOOR FINISH
WEATHERPROOF
iron wire to insure tight joints. ~ APPLICATION
Use flat block Insulation. Stainless steel band and fasten as shown. Point up joints and fill voids with hydraulic setting cement.
Use metal mesh blankets with 1" hex mesh galvanized wire netting on vessel side and expanded metal lath on outside. Tie and band as noted.
Heads - Apply 1" hex mesh galvanized wire netting and cover with hydraulic setting
insulating cement 3 8" minimum thickness.
Body - Protective Jacketing - See
57
Heads - Apply two 1 8" layers asphaltic mastic emulsion with glass fabric between layers. Body - Protective Jacketing
Where top of vessel may te sutject to walking or other mechanical injury - See page 120
Where entire boay will be exposed to severe mechanical Injury - use block Insulation. For application detaijj
see page 117 .
''
. ;* **' *y*; r>;
'J.* . 1 * .*
-
; S T 0 0 00 830
( 2.0 VESSELS EXPOSED TO MECHANICAL INJURY.
page 120
sure tight joints.
APPLICATION
HEADS
Use flat block insulation, stainless steel band, and fasten as shown. Point up joints and fill
voids with hydraulic setting cement.
BODY
Top 1/3 .(120)
Bottom 2/3
Use ulock insulation, single or double layer as required. Point up nil joints with iiyUt-ulic setting cement and band as noted.
Use metal oesh blankets with I" hex mesh galvanized wire nettin? on vessel side and expanded metal lath on outside. Tie and stainless steel band as noted.
INDOOR FINISH
Heads - Apply 1" hex mesh galvanized wire netting and covet with hydraulic setting cement 3/8* minimum thickness. Body - Protective Jacketing * See page 57
WEATHERPROOF Heads: Apply two 1/8" layers asphaltic mastic with glass fabric between layers.
FINISH
Body - Protective Jacketing
Wherte;any mechanical Injury will be anticipated due to persons working or walking on top of vessel.Use this method' '
For severe mech^fiical damage, use as on page 117. . v(
jTEf Platforms and walkways should be provided for normal operating access to top of the vessel. Thls-^^at*^*^
Standard is intended only to reduce insulatlon'damage resulting from inadvertent walking on vessels such*as
may occur during construction work.
' V -JP-h'-iy V ^
.* *. .! .*
*i'f
ST000083I
page 121
BLANKET INSULATION ON VERTICAL VESSELS, 48" O.D. TO 12'O'* O.D.
' block insulaiion
Stainless steel bands - see page 145 Weather Seal- on top head, outdoor only. Cover with Vaporscal mastic and glass fabric down to a feather edge over protective jacket and mastic emulsion - Sec page 151
Support and tie ring - see page 146
Metal mesh blankets Monel wire to support rings & tie blankets together with clinched staples or loops of 1> ga. black iron wire, b" to 8' apart. Stainless steel bands - Use 3 per blanket width.
Support ring - spaced at approx. 15-0* intervals -
Protective jacketing - see page 57
-Head tie ring
Sheet i
metaTto -project l*f
to provide
.Finish - seeceToA
watershed and
stop wicking.
Arc sunnort for vessels 8' -0' dia. and larger See page 146. APPLICATION
HEADS
Use block insulation stainless steel band, as indicated. Point up joints and fill voids with hydraulic -etting cement.
BODY
Use metal mesh blankets with 1* hex mesh galvanized v/ire netting on vessel side and expanded metal lath on outside.
Hang from support rings, tie together and band as noted.
INDOOR FINISH
Heads - Apply 1* hex mesh galvanized v/ire netting and cover with hydraulic setting insulating cement 3/8' minimum thickness.
Protective jacketing - see page 57
WEATHER
PROOF
FINISH
Heads - Two 1/B' layers of asphalt mastic with glass fabric `between layers.
Body - Protective Jacketing ' V V ' ' ' ``V
Alternate when specified: Weatherproof felt with V faps^fn'cach dtoctTonJ%^
seams with
staples on 2 "centers and band with 3 S.S1 band^per."*"!`v
,
Where body will be exposed to severe mechanical
ST0000832 page 122
BLOCK INSULATION, FLAT HEAD VERTICAL VESSELS
See Detail below
Build up in center v/ith Mineral Wool . cement or hydraulic setting cement & slope to the edges.
eatfierseal on Top Head outside only. Cover with Vaporseal mastic and qlass fabric down to a feather edge over Protective Jacket and Mastic Emulsion Seepage 151.
Protective Jacketing See page 57
Block Insulation
Point up and fill a(( voids with Hydraulic Setting cement.
Use 2 bands per section of block
Tie ring
install Flashing around all necks
& brackets. See page 151 -
Bow insulatHM - secure with copper wire w Stainless Steel hands. Finish in l'<" tc laaulat finishing cement Grade or platform
Cement block to lower head with fibrous adhesive
Sheet metal to project 1" to provide watershed and stop wicking.
Supports
Weatherproof Finish
Bevei Mecv at 45
Flush with Mock on top head stainless steel t>d in place cement as shown
'Heads - Apply two 1/B" Layers of asphalt mastic v/ith Glass Membrane Fabric between Layers
Body - Protective Jacketing
ST0000833
page '23
BLANKET INSULATION, 48" O.D. AND LARGER, FLAT HEAD VERTICAL VESSELS
C
Block insulation
wire
or stainless steel band in
place.
Seepage l4fr
Tie Ring-
iDE
j. I.<-
^T7T77-tV'//.
Metal mesh blankets -Monel Y/Z/////////,
wire to support ring, fasten Y?jr77S77/j'/77. edges of mesh together with
clinched staples or loops
of lb ga. blk. iron wire
Stainless steel bands
Build no in center with Mineral V/ool or hydraulic setting cement - slope to the edge.
Weatherseal on Top Head outside only. Covci will) Vaporseal Mastic ano Glass Fabric flown to a Feather Edge over Protective Jacket and Mastic Emulsion. See page lb'1
Protective Jacketing - See page 57
Install Flashing around all necks & brackets
C
Tiering ----------------- -- >
Sheet metal to project 1" to provide a watershed and stop wicking.
Block insulation; secure with wire or stain
less steel bands. Finish with !i' thick hydraulic setting cement. Grade or Platform
Cement block to lower head with fibrous adhesive
Y/EATHERPROOF FINISH
.
Supports
Heads Body -
Apply two 1/8* layers of asphalt mastic with glass membrane fabric between layers. Protective Jacketing
Flashing - Seal around projecting nozzles, supports, etc.
ST0000834
page 124
APPLYING INSULATION ON CONE BOTTOM VESSELS
Break line
Body Insulation
Support & Tie Ring,
Block insulation csten to tie bars using copper ' wire or stainless steel bands.
Point up and fill voids with Hydraulic Setting cement. Finish - see below Clearance for flange bolts.
INDOOR FINISH WEATHERPROOF FINISH
Apply 1" Hex mesh galvanized netting and cover with hydraulic setting cement 3 8" minimum thickness and cover with Osnaburg Rag
Apply two 1/8" layers of asphalt mastic with glass membrane fabric between layers.
Flashing - Seal around projecting nozzles, supports, etc.
ST0000835
page 125
CONTRACTION AND EXPANSION JOINTS '
Cold Temperature Equipment
Cold equipment insulated with cellular glass will be considered first. Although the intent of this practice is not to discuss specific materials and their application, cellular glass has properties so different from others that it must be considered in a separate generic classification.
Cellular glass, which has a vapor permeability of 0. 000000 + is more vapor resistant than most vapor-barriers. By sealing cellular glass to itself with vapor sealers to form a complete enclosure around the vessel or equipment, the insulation forms its own vapor-barrier, and none is needed on its outer surface. However, it is important that it be installed in such a manner that these joints remain unbroken. The cellular glass insulation system should be so designed that movement, due to contraction of the vessel or equipment, is not transmitted to the insulation to cause opening of the sealed joints. The vapor sealer chosen to seal cellular glass must be selected with care. Because of its vapor resistance, sealers containing high solvent content will not dry when placed between butt ends of the insulation. For this reason, the sealer should be of high solid content and it must remain elastic and flexible to the lowest temperature to which it is to be subjected. Sealers containing water, or which become brittle and shrink at low temperatures, are not suitable.
The coefficient of expansion (or contraction) of cellular glass is 0. 0000046, and that of steel, which has the lowest coefficient of the commonly used con struction metal, is 0. 0000065. Thus, when cellular glass is installed on a vessel at atmospheric temperature, and the vessel's temperature lowers, the circumferential dimension of the vessel reduces more than the circum ferential dimension of the cellular glass for two reasons. First, the higher rate of contraction of the vessel, and second, the service temperature of the vessel is reduced almost twice the reduction of the mean temperature of the insulation. Thus, the vessel "pulls away" from the insulation, leaving a void. This void causes no harm to the insulation itself, but it does leave it with no "backing. " Therefore, any pressure on the outer surface may break the vapor sealed joints of the installed insulation.
The insulation must also be designed to accommodate any axial contraction
of the vessel. On the cylindrical surface, this change in dimension must
be taken up by insulation contraction joints. The spacing of these joints is
based upon the movement of the vessel and the weigh*
'--
supported.
C
:STDOC0836
page 126
Cold Temperature Equipment (Cont'd.)
On vessels operating below -100F., these joints should be spaced on approximately 12 foot centers. On vessels which operate above this tempera ture, the spacing is generally determined by the weight of the insulation being supported by itself at its bottom. The maximum spacing of supports should be 18 feet on centers when based on weight alone.
A contraction joint is always required just below the top on vertical vessels, as the contracting vessel will pull away from the top, leaving a void below if a joint is not located at this position.
Cellular glass should be installed in broken joint construction. On all installa tions of very low temperature insulations, broken joint construction is used for several reasons. First, it reinforces the joint by providing a back-up under it, and second, if the service temperature is below -50F., many sealers will freeze, harden, and cause spalling of the cellular glass. Frequently, one sealer possessing extremely low temperature properties is used on the inner layer, and another to seal the butt joints of the outer layer.
Cold equipment and piping insulated with organic foam has contraction problems ' ' just the reverse of that of equipment insulated with the cellular glass just described. This is because its coefficient of expansion (and contraction) is 0. 000040-0. 00005. In this case, the insulation contracts more than the vessel.
In most instances, these materials are more resilient than cellular glass, but they have a much larger coefficient of expansion than the metal itself. This creates another set of problems. The outside of the insulation surface at ambient temperature is about stable in dimension, whereas its inner dimension shrinks. Around a circular surface this creates a condition which leaves "V" shaped cracks. On small and moderate pipe sizes, when insulation can be foamed oversize and the bands tend to draw and compress it to a smaller circle, this action cam be controlled relatively easily. On vessels, the problem must be dealt with as a basic problem of contraction. The way this is done is to provide a thickness of cushion blanket which can be compressed down to the circumference of the foamed insulation at the temperature of the vessel. The insulation must be pulled into this position by use of a stretched expansion or nylon band. See page 131 .
To compensate for these factors on vessels operating below 32F., the recommended construction would be to have a thick layer of non-compressed cushion blanket, double layer, sealed joint construction with the best sealed vapor-barrier possible. If located outdoors, a weather-barrier over the ' vapor-barrier is recommended. All projections, nozzle insulation covers,
ST0000837
page 127
Cold Temperature Equipment (Cont'd.)
inside and outside corners, must be carefully vapor sealed to prevent the vapor from by-passing the areas covered with the vapor-barrier.
Moderate Temperature Equipment
Moderate temperature equipment (above ambient temperatures to 212F.), because of its smaller problem of expansion or contraction, has less supporting and securing problems than either low or high temperature service equipment. If the insulation is dimensionally stable and has even a moderate compressibility, the blocks or curved segments can be applied directly to the surface and secured in position without space allow ance for vessel movement. However, because of the limited heat available for water evaporating purposes, if located outdoors, or where the equip ment can become wet, it is vital that either the insulation be moisture repellent, or that the weather-barrier keep the insulation dry. Once the insulation is water soaked, the temperature is not high enough to provide a vapor-driving force that will dry out the insulation in a reasonable length of time.
High Temperature Equipment
High temperature equipment (above 212F.) gets back into the range where expansion movement must be considered. Again, because of the number of variables, there is no clearcut guide to follow. The effects of circum ferential expansion on the tightness of the insulation joint is a function of the size of the vessel, its temperature, the shrinkage (or expansion) of the insulation, and its compressibility.
Such commonly used high temperature materials as Careytemp 1500 should be installed in wedge-shaped or curved segments. Kerfing and breaking blocks around cylindrical vessels cannot give as efficient an insulation application as properly cut and fitted segments. The resulting voids from such kerfing will reduce the thermal efficiency of the installation. If it is attempted to fill the voids completely with insulating cement, the resulting labor cost would be much greater than the proper cutting of the insulation. For vessels up to 10 feet in diameter and 400 F. in temperature, if the r circumferential block is cut and fitted to be 1/2 inch greater in circumference
'ST0000838 page 128
than the vessel, and secured so that the tension of bands produces the compression on the butt edges rather than on the surface toward the vessel, this little space and the compressiveness of blocks will most often suffice to take care of the expansion of the vessel. On vessels of greater diameter, definite provisions for expansion should be made.
Of course, the metal of the vessel is the controlling factor in the expansion of that vessel. To illustrate the dimensional changes of a vessel, see page 134. This Table gives the dimensional change in diameter and circum ference of various metals at various temperatures and diameters of vessels. As can be seen from this Table, the changes in these dimensions are sig nificant, and the installation design must make certain that the increases in dimensions do not open joints and ruin the installation. Of course, to these expansion figures must be added any shrinkage of insulation caused by temperature.
Numerous methods are used to provide an expansion area around the shell of a vessel. First is to wrap asbestos rope around the vessel; second, to place stainless steel, spring type bands around the vessel; and third, to install compressible blanket around the vessel, prior to the application of the insulation. The use of multiple layer, broken joint construction rigid insulation also helps, as there is bound to be an added degree of flexibility with multiple layers as compared to a single layer. In addition, any joint opening is restricted to only one layer, and there is always at least one layer left to act as a heat barrier. This reduces hot spots and heat dis integration of the-weather barrier. These methods are illustrated on page ^33. of course, the block must be cut and fitted to the outside radius of the vessel plus the thickness of the spacer used. The insulation, when installed, should not compress the rope, spring band, or the blanket, otherwise they will not serve their purpose in allowing for the expansion of the vessel.
Where circumferential expansion control is necessary on the side walls, it is also necessary on the heads of the equipment. Use of compressible blanket under the rigid insulation on heads is easier to install than rope or expansion bands, and for this reason is more frequently used than the other two methods.
Use of Flexible Insulation in Combination with Rigid Insulation
Recovery is the ability of a material to return to its original size or form after it has been forced into a shape other than its original one. In installa--. tions where it is installed to a permanent shape other than its original, &$&
' -``ki- .TSgr"'
ST0000839
page 129
Use of Flexible Insulation in Combination with Rigid Insulation (Cont'd.)
exce ssive ability to recover is not an asset, and may be even detrimental. However, where the substrate changes position, size, or shape, recovery may be a most important property.
Because of these particular properties, blanket and flexible insulations are frequently used with rigid insulations to act as mechanical, and some times thermal "cushions. " Page 130 and page 132 show methods of using a flexible insulation (most frequently fibrous blanket) to compensate for expansion of a vessel so that the joints in the rigid insulation remain tight. In the case of hot service, the flexible insulation should not be compressed during application. On low temperatures it should be compressed sufficiently so that the insulation's recovery faculty will expand it as the vessel contracts, ouch applications are not necessary at moderate temperature differences and on small diameter equipment, but are essential where differentials from atmospheric temperature and equipment diameters are large. The larger the diameter, the smaller the temperature difference at which this type of con struction becomes necessary. Care should be taken not to have expansion forces exceed the strength of the band securement.
On linear expansion joints, the situation is reversed from cylindrical expan sion or contraction. The flexible insulation used in linear butt joints is compressed as temperatures drop below and expand as they rise above atmospheric. See page 89.
C
* o *
<D
--
CM
ST0000840
page 130
METHOD OP COMPENSATING FOR VESSEL EXPANSION AT SUPPORT AND STIFFENER RINGS
PROTECTIVE JACKETING
5/8MX.015 STAINLESS STEEL BANDS
INSULATION FILLER; CHAMFER TOP 45 (SEE NOTE) MASTIC (SEE NOTE 2) Vq THICK ASBESTOS CLOTH INSULATION SUPPORT RING (SEE NOTE) STIFFENER RING PACK WITH MINERAL WOOLOR BULK GLASS WOOL. 26 GA. 302 STAINLESS STEEL FLASHING.
WEATHERPROOFING INSULATION
VESSEL SHELL (INTERIOR)
AT INSULATION
SUPPORT RING
NOTE: INSULATION SUPPORT RINGS ARE SPACEO ON le'-rCTRS. THEIR WIDTH IS TWO THIRDS THE THICKNESS OF THE INSULATION.
AT STIFFENER RING
NOTE: THE INSULATION FILLER PLUS THE VESSEL INSULATION MUST HAVE A TOTAL THICKNESS NOT LESS THAN THE WIDTH OF THE STIFFENER RING. THIS DETAIL IS REOUIRED ONLY WHEN STIFFENER RINGS ARE WIDER THAN THE THICKNESS OF THE INSULATION.
-GENERAL NOTES-
1. FOR INSULATION MATERIALS, THICKNESS,WEATHERPROOFING,MASTIC & BANOS, SEE SPECIFICATIONS.
2. FOR SERVICES WITH METAL TEMPERATURE 250* F. OR LOWER
INSULATION IN MASTIC AS SHOWN.
'
-r. :
ST 00008UI
page 1??
C
METHOD OF INSTALLING ORGANIC FOAM ON LOW TEMPERATURE VESSEL TO PROVIDE FOR COMTRACTIQNJ
5TRETCH BAND UNDER TENSION
CURVED SEGMENTS OF ORGANIC FOAM
.CUSHION BLANKET NOT COMPRESSED
BLOCKS CUT LARGER THAM VESSEL SO THAT CUSHION BLANKET IS NOT COMPRESSED V/HEM BLOCKS ARE STRAPPED TIGHT
AFTER INSTALLATION, B'JT BEFORE TEMPERATURE IS LOWERED
c
STRETCH BAND
CURVED SEGMENTS OF ORGANIC FOAM.
MOTE.:
51NGLE LAYER SHOWN.
IF TWO LAYERS ARE INSTALLED,
SECOND SHOULD BE INSTALLED
WITH BROKEN JOINT CONSTRUCTION,
ALSO WITH TENSION BAND.'
ORGANIC FOAM CONTRACTS
MORE THAN STEEL VESSEL.
T
w <s'<r CUSHION BLANKET
^ COMPRESSED
Ri IS LESS THAN R
AFTER TEMPERATURE IS-LOW
ST0000842
page 132
USE OF FLEXIBLE 1KJSULATION IM COMBINATION WITH RIGID INSULATIOM TO COMPEMSATE FOR VESSEL gXPAMSlOM
RIGID INSULATION
FLEXIBLE IMSULATIOM VESSEL WALL
RADIUS OP VESSEL AT 'ELEVATED TEMPERATURE RADIUS OF VESSEL AT ATMOSPHERIC TEMPERATURE RADIUS OF RIGID IMSULATIOM REMAIMS UMCHAMGED,THUS BUTT -JOIMTS FLEMAIM UMCHAKJGED (CUT TO FIT VESSEL RADIUS PLUS THICKNESS OF FLEXIBLE IMSULATIOM)
FLEXIBLE IMSULATIOM WHICH WILL COMPRESS TO COMPEMSATE FOR IMCREASE OF VESSEL RADIUS
ST0Q00843
page 133
TWO METHODS USED TO PROVIDE FOR HIGH TEMPERATURE VESSEL CYLINDRICAL EXPANSION
C
MINERAL OR GLASS_ WOOL BLANKET
VESSEL WALL
MULTIPLE LAVER RIGID CURVED SEGMENT OR BEVELED BLOCK INSULATION
INSULATION STRAP
METHOD i
1
NOTE -
SINGLE LAYER INSTEAD OF MULTIPLE LAYER MAY BE USED IN METHODS SHOWN. CHOICE DEPENDS UPON TEMPERATURE AND SIZE OF VESSEL.
. S~CCGC344
page
TABLE 5 .2
C
k
CV`00*!)q>\9^0
S!2s^ss
O vs
oj o OK
OOCSvlviOi^^ o (K's c\j `S \j <d
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O ^$0 O
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v
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o
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0 xl
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0
l
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< O, 10 \S
6 dOo
^ ? M ? X ^ N1 ^ ^ o,
ss^'-s 5 'q 0 <s
*41 *o
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0 CJ O tty
*0 o cs o 6 q o' o o d C5 0` Q d o o d o' d O' o' d o' d a
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sj. *o j *> <>. *o o !fi> aj t?i *?S Vj '-\S- \ *0 ^ *o 0 c'> ^ i 0 '4 0 SJ. n *0 vs d
cs -<
d <$ d n. o; i 6 0 0 ^ O ^ Vj Q >* 0 >F V9
^T *J
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3^5
<<4. O ^
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Q ^ S- N O Vr\ Oy fry
?$| <5 < s. cvj ^ VJ vi
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'Ci \r>
*Q \3 5 > <f f\ Ci ^
<5 *< "> ^ t< 0 $
V*. C| 0^ TJ ;, <o ^ >o
< O <t)' t{)
o \s n O d'cojv
'O < "3 \t n p t \v Q
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c> \3
4b^" O d *< <>i *3 ^ Wj Vo 0> k ci i<^ vi N
O 5 Cj
^ 5> c% V, ^ ^0,^0
d "C v: *j
Ik
O
Q
Q:
<N*0<^\j.<.Cv.>i'^
> o ^ o> tC ^ -v ^ ^
vs *2
O' O Of v: C\j oj o ''* 0 0 < < c\i ri ^ QWCi
^ <0<N O do
O O*
\ *0
0 2^ ^ K o vN s
vs O tt',
v. o^> . 0 >l *o "v
H >a
\J 'O
o, > va o>
OC><SO <"C<ei 0oc5,<^<^cv d o d < O' d O' <
<4 sii S
'J ^
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OO0O oooo
Cv,*0'Vv5tOQCS,>:}-
QOO 00.0 o o
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5ooo o o C3 ^3
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**> \}- \S
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0000
01 *1 ^ v -:':{*rf- :
5O L-<i
QQ: tj:
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ST0000845
page 135
ALUMINUM FOIL ON VERTICAL VESSELS, 48" O.D. AND LARGER
Vt Dia. M.S. Bar
i--i I i--r~
jm.
i--i i--r
DETAIL OF SPECIAL PENCIL ROD SUPPORT BAR ("A" Dimension will vary with width of foil used)
Aluminum Foil
Protective Jacketing See page 57.
rod support
Extra support rod around necks
DETAIL OF TANK TOP
3qo Flashing plate V' x 4" continuously welded around bottom of vessel at tangent line. Std. pencil rod tie bar. Use block, band as on page 145.
1.0 MATERIAL
APPLICATION .002" to .0045" thick fully annealed pure aluminum foil in rolls, 12" to 14" wide.
2.0 BODY
Weld special pencil rod support bars vertically around shell at approximately 15" centers, lining up the outer openings. Lace aluminum foil thru outer openings completely around circumference.
3.0 TOP .HEAD
Same as for body above. Use extra support bars around nozzle openings. See detail above.
4.0
BOTTOM HEAD Continuously weld 1/8' x 4* flashing plate all around bottom head as shown. V/eld stand" pencil rod to flashing plate. Use IK' thick block insulation stainless steel band
: ^ Cc
5n i*' 8 V
page 136
5.0 FINISH
Body - Protective Jacketing. metal to flashing plate.
Extend sheet
Top Head - Apply protective jacketing fastened as above. Extend protective jacketing down over protective jacketing on body.
Bottom Head -
Indoor - Apply 1" hex galvanized wire netting and cover with V' hydraulic setting insulating cement.
Weatherproof - Apply 1" hex mesh galvanized wire netting and two 1/8" layers of asphalt mastic emulsion.
6.0 NOTE:
This method can be used on tanks to prevent auto ignition conditions resulting from product leaks or spills. It should be used only with approval of Plant Superintendent. This method has operated on temperatures up to 360F.
7.0 REFERENCE See Auto Ignition, page 9.
ST0000847
page 137
APPLYING STYROFOAM TO ROUND VESSELS, UP TO 12'0" O.D.
O.D. of vecMl
c
For ends of vessels, seepages 139 and 140.
. STOOOOS'+S
page 138
0
1
Slob width
AB
fl
o T3B
0.0. of Vessel
Thickness of insulotion
METHOD OF CUTTING SLABS
OUTSIOE OIAMCTCR
ri> I*
9**6" 9'*0" 8'* 6" 8'* 0" 7*-6" 7*-0"
? S**6"
6'*0" 5*-6*
NUMBER OF PIECES REOUIRED
72 72 72 60
CC
oca-min. 2* 30* 2*30' 2* 30' 3*0*
8
INCHES 5*,* 5\6 4% 5s',6
60
3* O'
5
60
3*0'
4"',S
52 3*30' 5*4
45
4* O'
5^,
45
4* O'
5`',6
45
4*0*
.4%
A IN INCHES FOR VARIOUS THICKNESSES
WHEN T 2*
WHEN -- ** T3
WHEN T 4"
PIECES TO 8E CUT FROM A
SLAB THIS WIOE INCHES
5*2 59/i6 cH/
12
5''4
c II. 5 '32
5*,s
12
5 *16
5*32
12
5%2
5%
523/32
12
57'32
5S',s
5 ,3's2
12
42%2
5
5*32
12
5 *'2 52%2
5% 5%
53'4
6
` 12 12
5%2
5*2
5%
12
4`S',S
5%2
57/32
12
5`-0* 40 4#30* 4 'is 5
5%2 5 s', 6
12
4'-6"
40
4*30'
4\z
4'7'32
4"',s
4^
10
4'*2"
36
5*0`
4T',s
4Z5'32
43,'32
5S'32
12
4**0"
36
5*0*
4'/4
4,9'32
42%2 43^2
10
3*-9-
36
5*0`
4
4"'32
4'7/32
42%2
10
3'-6"
40
4*30'
39/32
3il9/'32
3%
52%2
12
3*'2"
36
5*0'
3%
3Z3'32
32%2
4%2
12
3*-0"
36
5* O'
33'.s
$%Z
32^32 3^32
12
2'' 10"
33
5* 30' 3*4
3%
3%
4
12
2**8"
30
6*0'
3%2
3%
4''.6
10
2*'6"
30
6*0'
3*/e
3l7'52
3%
33,'32
12
2*"0*
26
7*0'
2%
37',6
,11. 3 'is
3,5',s
12
r-e *
24
7* 30'
2`%2
3*8
3%
3%
12
r* 6"
; r-4"
r- 2" 1
23
22 20
8*0'
8* 30'
9*0*
2 '32 2 2^32
35/32 Z'%2 2^2
3% 3%
' 35/32
3**32 3*32
A.
12 12 10 . .
t'TiV i
STYROFOAM SEGMENTAL BLOCKS
NUMBER OF PIECES PER SLAB WIDTH
2 2 2
2
2
2
2
2
2 2
2 2 2 2
2 3 3 3 3
3 3 3`
3
T* * *NI
r
ST0000849
page 139
APPLYING STYROFOAl^TO DISHED HEADS
For shell insulation, see page 137 Wood skewers
Styrofoam curved blocks, see page 110.
Head bands space so that all blocks are held in place by at least one band
Stainless steel bands 5/8* x .015'
Install 3 bands on the end - fasten bands to these
APPLICATION TO OISHEO HEAOS 72'DIA.
INDOOR & OUTDOOR FINISH - Heads Apply 1/8* minimum thickness of mastic emulsion; while wet, imbed glass membrane fabric and follow with 1/8* final layer of asphalt mastic.
Body Apply protective jacketing,'see page 57.
ALTERNATE WEATHERPROOF FINISH- Heads* Apply 1/87J-,
___
minimum thickness of
mastic emulsion; while wet, embed glass membrane*
fabric and follow with 1/8" final layer of 4010 Vaoorseal mastic
, ST0000850
page 140
C APPLYING STYROFOAM TO FLANGED HEADS
NOTE: If head is dish*.: and vessel is larger thon 36* dio., use boards to cover heads. INDOOR AND OUTDOOR FINISh: Heads: apply 1/B" minimum thickness of ospholt mastic emulsion; while wet,
Imbed glass membrane fabric and follow with 1/8* final layer of csphalt mastic.
Body: apply protective jacketing ; See page 57.
ALTERNATE * WEATHERPROOF FINISH: Heads: apply 1/B minimum thickness of aspholt mastic emulsion; while wet, embed glass membrane fobric and follow with 1/8" final loyer of 4010 vopor seal mastic. Body: opply protective jacketing -
ST000085I
APPLYING STYROFOAM*^TO VESSEL SUPPORTS
page 141
Bottom of shell of horizontal cylindrical vessel
C
ito oakwood block or high density Styrofoam H0*2, check for bearing stress
Steel bar frame I* x X' *0 hold block in position
LONGITUDINAL SECTION THRU SUPPORT
SECTION A-A
APPLICATION TO SIDE SUPPORT
Note: Hijh density Styrofoam HD*2 may bo used in place of wood Mocks. Allowable compressive strength -- dOpsi
end view of support
ST000C852
page 142
APPLYING STYROFOAI^TO FLAT WALLED VESSELS
j
r
j
ELEVATION
r/ i
Boards coated on back and edges with cold setting cement and stuck to wall of vessel. Wooden tank cover.
NOTE: If successive layers are required, apply in same manner. Stagger all joints in successive layer with previous layer. Use 2 skewers per square toot to fastens uccessive layer to previous one.
Floor line
Concrete base
SECTION A-A
Wood cover
Glass fabric - seal to steel with No. 4010 mastic.
NOTE: High density Styrofoam HD-1 or HD-2 may be used under equipment where compressive loads are too great for regular Styrofoam.
12" V/ide x 9'-0' Styrofoam boards. Cement to vessel wall using cold setting cement.
Styrofoam boards coated on edges with cement Do not cement to concrete base.
Seal this joint with cold setting cement
Concrete base. Extend base to outside of insulation.
INDOOR & OUTDOOR FINISH: Heads: apply 1/8' min. thickness of
mastic emulsion; while wet, inbed membrane fabric and follow with 1/8*
final layer of
mastic.
Body: apply protective jacketing, see page 57.
ALTERNATE: WEATHERPROOF FINISH: Heads: apply 1/8' min. thickness of asphalt mastic emulsion; while wet, embed glass membrane fabric and follow with 1/8' final layer of 4010 vapor seal mastic.
oooy. apply protective jacKeung,
ST 0000853
page 143
ETHAFOA# APPLICATION
1.0 APPLICATION:
1.1 BODY:
Use flat boards of expanded polyethylene with molding skin left on but with edges trimmed and squared. Wrap boards lengthwise around body with end joints staggered and fasten with stainless steel bands.
1 Layer - Band as shown in sketch on Pape 144.
2 Layers - Stagger all joints and apply both layers together banding second layer only as shown on detail drawing.
Multiple Layers - Make application in multiples of two layers banding as per 2 layers above. If number of layers is odd. apply last layer as per 1 layer above.
1.2 PLAT HEADS;
Apply as indicated above using stainless steel bands, 5 per board width.
1.3 DISHED HEADS:
Apply first layer as shown on page 144. Second and successive layers to be installed same as first layer but rotated 45 from previous layer. Each layer to be fastened with 3 stainless steel bands per board width plus sufficient number of diagonal stainless steel bands to fiimly secure the insulation to the heads.
1.4 SUPPORTS
Insulate around supports by methods shorn on page 141 using HD-2 Styrofoam in place of wood blocks.
1.5 INDOOR FINISH:
1.51 None required. May be painted if desired.
1.52 Alternate when specified - cover body and head with one 1/8" wet layer of Insulmastic No. 4010 vapor barrier or other suitable mastic.
1.6 OUTDOOR FINISH:
1.6l
Heads - Apply one 1/16" wet coat of Insulmastic No 4010 reinforce with glass membrane fabric and apply second 1/8" coat, of Insulmastl No 4010 or other 'suitable'.'nas^Ic3^M
ST0000854
BANDING PATTERNS FOR EXPANDED POLYETHYLENE
page 144
1st Layer 2nd Layer
ST 0000855
M5
BANDING PATTERN FOR BLOCK INSULATION
Block insulation
c
Nozzle long enough for 3* of (lashing between the insulation and nozzle flange
Jfozzle diaaeter plus 6*
Vh Floating tie ring 3-8*dia. '/J bar with ends welded
together
DETAIL A
Bands fastened to
tie ring
Use 2 bands for vessels up to 48" 0.0. and 3 bands
DETAIL A For heads 36 O.D. and larger with nozzle over 6" size.
DETAIL B For heads 36" O.D. and lorger with or without nozzles up to 6" size.
DETAIL C For vessels up fo 35" O.D., or where welded or bolted fie ring cannot be used.
NOTE:
M
ALL BANDING SHALL BE 5/8" X .015 STAINLESS STEEL.
ALL WIRE SHALL BE NO. 16GAUGE MONEL OR COPPER.
;
IN CASES WHERE BANDS CANNOT BE USED, MONEL WIRE MAY BE USED IF '
SPECIFIED OR APPROVED BY DOW REPRESENTATIVE.
':/* V-*
ST0000856
page 146
INSULATION SUPPORT AND TIE RING, WELDING DETAILS
t
DETAIL OF PENCIL ROD SUPPORT AND TIE BAR Hay be stocked In straight lengths lor field installation.
o.o. < Vessel
END VIEW
SHOWING TYPICAL APPLICATION OF PENCIL ROD
ST0000857
SUPPORT AND TIE RING FOR INSULATION ON LINED OR ALLOY VESSELS
page 147
c
c
Insulation Thickness
/
Size of Angle
/ * / 'x#'
//'
2'
2im 2*x2*xj' 3m 2/'x2ix^ 3i' 3*x 3*xj'
Gage
/' //
Bolt Size s/,e
i'
*'
i-
/'
/'
Note:
For vessels over 8'-0" dia. make ring in 3 equal parts.
Notes:
~ 1. To be used fa Insulation support on vertical vessels or for
tie ring adjacent to dished heads, when welded type ring
c^anno.t .b. e used,
t. r
2. Fa welded on support and tie ring see page 147;
"Xit
ST0000858
page 148
t
POSITION OF STRAP With Respect to Weld Bead (f \
Ur?
DESCRIPTION
"Greg Strap" is manufactured of mild steel by Greg Manufacturing Co., 4947 S. Flajole Road, Midland, Mich. It is flexible, easily cut and can be bent by hand.
USES
1. Head tie ring on horizontal and vertical vessels when welded ring is not provided.
2. For lined vessels or in hazardous areas where welding cannot be done.3
3. May be used on flat surfaces by tack welding at close intervals.
3.0
STQ000859
GREG MANUFACTURING COMPANY 4947 FLAJOLE ROAD MIDLAND, MICHIGAN
page 149
c
USES
1. Head tie ring on horizontal and vertical vessels. May be used on flat surfaces by tack welding at contact points.
application to dished head
STQ000860
page 150
C WEATHER SEAL AT RINGS ON VESSELS
Vessel shell Insulation Protective Jacketing - See p&qe- 57. Flat M.S. bar 2" x 1/B"
Protective Jacketing, when required with No. 7 round head sheet metal screws at 12" centers
Channel stiffener 1/B" Cont. seal weld.
DETAIL "A**
c VESSEL WITH CHANNEL STIFFENER
ST000086I
FLASHING DETAILS
page 751
C
i
detail a
Nozzle not insulated
-------- &
DETAIL B Insulated Nozzle
C
DETAIL C Insulated Body Flange
DETAIL D For Support lugs, platform brackets
LEGEND
Vessel wall
Vessel insulation
First coat of weatherproofing vaporseal mastic
Stiffening
Prime metal with priming mastic
Glass membrane fabric
;'
' Final Vaporseal mastic coat
'**' *:
"If bar projects 2"or less, .
, .. . cover completely with
DETAIL E aft . fV
Stiffening Ring
ST0000862
REMOVABLE INSULATED COVERS
page 152
X" Clearance Wire together at corners and all seams Sym. about centerline
fC
1" Min. flange width-----
For Protective Jacketing Covered Vessels
Fold cover flange back over bands
Insulated Cover same as Detail A
fC
. detail B / For Mastic Covered Vessels
Vessel shell Vessel insulation Protective Jacketing -- Seal joints with flashing mastic. No. 7 x Vj" R.H. sheet metal screws on 4" centers. Type HL metal mesh blanket insul ation with expanded metal inside thickness as specified. Protective Jacketing with weather tight joints.
Hold insulation to metal cover with No. 12 Ga. v/ire hair pins soldered to inside of cover.
X" x 3" Lg. Monel machine bolt
Hold cover in place with 5/8" stain less steel bands with ends connected by X" x 3" long draw-bolt.
2" min. flange width
X" x 1" Slot (2) in flange Seal all around with mastic
Note: Disconnect davit from man hole cover and swing davit I clear insulated cover.
. .v:
- .-.-V mm&mmm
^ H ,-l\
ST0000863
page 153
1.0
PRESSURE VESSEL NUMBERS, OPENINGS OR BRACKET Sections shown below
(Omit drip edge & flashing mastic on indoor finish)
For flashing over bevel and onto bare vessel and onto Protective Jacketing.
Vaporseai mastic shall be applied in two 1/8" coats with glass fabric between.
Use No. 4010 vaporseai mastic for vessel temperatures up to 250 degrees Fahrenheit. Use Eagle-PIcher "Stalastic", High Temp. Grade for temperatures ever 250 to 500 degrees Fahrenheit. Hs Height of P.V. Numerals T= Thickness of Insulation
$TC -> n n 8 5 -
page 154
2.0
c DETAIL OF BRACKET SCALE- 3"= I'-O11
NOTE* FABRICATE AND COMPLETELY ASSEMBLE BRACKET. AFTER COMPLETION DISASSEMBLE AND FASTEN TO OR PUT INSIDE THE VESSEL IN SUCH A MANNER THAT THE DISASSEMBLED PIECE WILL NOT BECOME LOST.
BRACKET-WELO TO UNIT ADJACENT TO P.V. No.
DEPOSIT DOW PRESSURE VES` NUMBER IN ^ WELD BEAD IN I; HIGH NUMERALS ON VESSEL.
:r` ;0-
it:; Ja m Z1V
IMS?
STD000865
>> 33 3^
3
a.
i
o a
/
C\
TABLE 5.4
^ ^ c <> * < *ir = 5^"^Cit5JS`iK;-S
M (.1 (.1 Ct u (A Ui ( (A m vt Cl i* *** r " r r r r * r =S'?c5'i`;`j*..-rc? f
s? 2n O3i *9
oX 5U UC4 N(J <(J> y(4>Ui. MU oU UJO U- pU M^pNMNKC* ^NKKxluM(J\)>M4W^M" y > = r-;
^wyK^^v!?p"^ aOeSU<4o>)*ittSuO
!v^tov<Ni.'vV'OXM^aouUN^XO
^,s is
r <
NC>iAXXUMMQXi){i SOfin5|15i>i*--0Jo.Nr?*y33'<*Ji;MiSNSn:l^N>
MNj0M*0W'VKJ) wMW,M*-wJKM> K--) M00n*0^>v)UMS<9Mmrae*gCoAuXUiNOl) X
C* > * --
j 3" ^
---pooo'S'O'O'J w cc m */ s v> e
ti S'2.?>
MUXSK^JU*0O<>MX ^--OOXCXSOx---VC3l 'ICj <UJ p&>(3O^XMO4so*i<C. UWN\)>N '3$r* *A
------
-- '0*0*0
bssblsaslsas:
A'O'Ooeiaacaooua 8K = as3ai:85;s
S-S S,;5
25
..
.svfwv :
i r .. :
!
SSL s6e!dd
' 4
.. .' - r.-r-: ;
<"' -: ' ` t: -xft#-
= ' '
i
1O
*nm
/.I B
11.|
r0$rQl
P C- 3
^a5.|J{ J2) c 3^{t
. A *
aQ
3
<r
\
ST0000866
AREAS
page 156
TABLE 5.4 (Continued)
i
f
g J Mil
wno-oao.o-o'T'oK
-oot*on rK< or vn< i-onaonOoonn NOrtP) nncinnv'tv
V*o Vv, f,S\ yo OOO* N**j *Of lv| ^o ^p * V */ *t w*ip? n v ui vi i if$
ut
11 0^<SAW;.u<o*. V7),
Ou>sN<On^N-aO)n*o><>o1rciQ:O.mn'O'*Na W-NNfNJNf'JWotpVNjMWrWt'ffVifHvWV
-n-io-'ONo.nvKO NoP^*n(NO(vy)r*-ONO{',S(v3 (K<4KCKi(<cj
wrt
r)
(r*
wN
>*
A
h
;o<l
Or)
rO)
nO
f)
m
n-
_ *o o JC
X8 <l vJ
ts'v**pf> WOr^* On 'S0.Z,0: ^*2KiJ0*N( nnoo. o^'fynfnNv' tnvotnvi)v*
On <V>- u) Cn'tl *Vf *v.>i *nrt NV| ^hi Oo J*0 N0
c,oioOooNfvx^>tonmrie-r-)v'joi^>f0o' >3v'0-o'`0k'0c'0o *<C\ orvnKrN* rsNkiNc
lid
SRsSSP.SfsSSSR -Nrt'fn^'oo^Owfi
" *7 *1 'I ^ ^ ^ w M ^ TM
VI o W V* %* | <0 <0 <o <o
** pj *o is ci
<o c* no
*4 PN N" fK> K?? ;KC KK NfO PNa ^(9 rO
f: 1
* fe',.
laSi
O1. pt% -J1rt*9rJtVJOt%'^J*.NX\cJJOIJ .*%-V'J* KK S NNNNNKTsNro
J*ku -o* -a* eJe vJ '/}9 *J*> oJ oJ * OJv *J9
_* V f f"'A'lJN | * f>i* .> -<> p*n* Jc- Ju*J> *c*-ix Jc. .< .* e**i i
-'v if*
! X'.'
! ?k5T-' '
STG000867
page 157
O'-d" P-0* r-4*
7-4-
3**0" 3*-4" 4*-0* 4'-6"
5*-0* 5'-6* 6'-0" 6'-6"
7'*0" 7*-6* 8'-08'-4"
'-0" 9*-4" 10'-0" IO*-4"
11,*0" 11*-4" 12MT IT'-O"
13"-0" 13"-4" 14'-. * U*-4"
IS'-O* lS'-4* 14'-0" l4*-4"
t7*-0' 17l-4" l3'-0"
l?'-0* 19'-4" 20'-0" # 2D*-6*
21'-0" 2l'-4* 22'-0" 22"-6*
23'-0" 23*-4" ?4'-0" 24*-4"
25*-0" 25*-4* 26'-0" 24'-4"
2r-o27*-6" : :* o* 23'-6*
$vrfoc<
AfW in Sq.ft.
.7854 3.1414 7.05:4 12.354 19.433
26.274 33.425 30.253 43.417
78.540
95.033 113.10 132.73
153.94 174.71 291.04 223.93
234.47
283.53 314.14 3*S36
323.13 415.43 432.37 490.S7
323.93 572.34
415.75 450.52
705.64 754.77 804.25 855.23
907.92 942.11 1017.9
1075.2
1134.1 1194.4 1255.4
1329.3
1335.4 1452.2
1329.5 1590.4
1641.9 17*4.9 IS07.6 1885.7
1943.5 2942.3 * 2123.7 2204.2
.
' 2370.2 ' 72-5.8
2443.0 2541.8
A2EAS AN'O VSLUr.n - S.'K* 25
Vohrr.s InCu.Fr.
.0454 .5234 1.7471
4.Icco 8.1312
14.137 72. V.7
33.510 47.713
65.453 67.114
113.10 143.7?
179.5? .223. C1 25.1. C3 321.55
331.70 448.92
523.43 436.13
696.91 774.33 934.73 1022.7
1150.3 12s:.2 -1434.S
1574.3
1747.1
1949.8 2144.7 2357.1
2572.4 2305.2 3053.6 3315.2
3571.4 3882.4
4183.3 4510.9
4349.0 5203.7 5575.3 5744.1
4370.6 4795.2 7733.2 7700.1
8181.2 8432.0 9392.3 9744.0
10304.0 ` 10S39.0 11474.0 17121.0
?!>
Total Ccfccity in Gallons
.4392 3.917 13.22 31.33 61.20
105.6 157.9 250.7 354.9
437.6 651.7 844.1 1076
1243 1652 2055 7435
2155 3353 3917 4524
5213 5757 67dS 76;}
$535 9637 10743 119M
1321? 14536 10M 17575
19213 T >2 22343 2475?
20654 29042 31334 33744
342.*3 33923 417C6 44615
47655 50332 54144 57401
41239 64745 6894 3 72390
77094' . 61455 ' 81731 9M7I
Cicsu.*:::
Sv?..:: /;CC Jr.
Sq.F.
29'-029'-430'-C* 30'-6"
31'-O3r-i" 32"-032-i"
2542.1 2734.0 2277.4 2722.5
301-7.1 3117.2 C-Zir.O 331C.3
33'-O' 3y-t* 3 P-034'-6"
3421.2 3525.7 3531.7 3737.3
35-'-C" 35'-6*
. ?6'-0' 35'-6'
5 3757.2 7371.5 4135.4
37'-C"
37'-4" 35'-C" 3a'-6"
43:3.0 44'7.9 4535.5 4613.6
3?'-0
3r'-5" 40'-0" 4C-4-
4773.4 4501.7 5325.5 5:13.0
41'-0" 41'-4' 42*-0' 42--i-
Sul.O 5413.6
Sill.o 5174. 5
43'-043'-5" 44'-0" 44'-5"
57 !' 7 332.1 4221.1
45'-C" 45'-4" 46'-0" 44'-6*
6351.7 6503.7 6517.6 6792.9
47*-Z * 47'-6" 4*'-0' 43'-5'
6737.0 7C33.2 72??. 2 7287.0
49'-" JO'-O' 5V-0'
7543.0 7(77.7 7051.0 7,503
60'-0" 65'-0^
70'-0" 75'-0-
11,310 13,7/3
15,374 17,67?
80*-0* 85*-0" 90'-0* 95'-0" - lOT'-O"
. -r?
'
> *
20.105 72,673 25,447 73.233 31,415
3- 1
::
TABLE 5.5
..
Volvns in Cu.Fr.
1777C.9 13442.0 14127.C 14351.0
15599.0 15351.0 171:7.0 17974.0
163 IS.0 I965J:. ~ 77552.0 21535.0
22447.0 23123.0 2-*0 21411.0
76522.0 27517.0 2'73I.C 2?8i3.0
31020.0 32*19.0 3351G.0 24;3i.O
35337.3 37523.3 237-2.0 40194.0
41633.0 43027.0 44-02.0 46i-'0.0
47713.0 4932=. 0 50715.0 57445.0
51362.0 51115.0 57736.0 597*1.0
61631.0 63534.0 65153.0 87,116
113,077 143,73,1 179,595 220,094
I 258,033 321,5a 381,704
: 448,9.*-: ,
Vs;' J,5/3 '*<
.* f'l. !.->.
'
To*al Cep- ' f InCv!*-:
10.:;-: 135*:2 nn:i
ll'55? I2JVA
i3< -:j
14723.1
I 53/47 I1C327
147^3 I7.'*.`i la-41 190:52
Ifil"
2I/723 723513
?5sr> . -1.V7 2.AJ72 2431
2-.-7.-j 27> 7--4 v;;;; :;:-47i
.
zvz:
31ii5!
255?:: :;::-'.7 :-?i2i5 jjj;;2
/C 5555
o:iiv
4535;? vi.}.:
411.473
8-.,C'* 1.075; 6"-? l;*'.li4'-l 1
SAFETY STANDARD NO. 45 ASBESTOS
ft A)oJ3
ST0002-983
SCOPE
This standard covers the safe work practices for handling, disposing and monitoring of asbestos and asbestos-containing materials.
POLICY
[t is the policy of the Texas Oivision to protect the health of its employees by minimizing their exposure to asbestos fibers. This shall be accomplished through education of employees, engineering specifications, safe work practices and the replacement of asbestos containing materials as quickly as adequate substitutes can be found.
Guidelines for implementation of this policy are contained in the Handbook For Handling Asbestos Materia;, copies of which may be obtained from the Safety Department.
RESPONSIBILITIES - OWNER (OR USER)
1, Supervision must ensure that all personnel comply with the established handling procedures as outlined in the above handbook. Supervision should also actively look for and evaluate asbestos substitutes.
2, Employees handling asbestos must follow the established procedures and use the necessary protective measures.
3, Contractor personnel must also comply with the procedures established in the above handbook.
RESPONSIBILITIES - SUPPORTING SERVICES
1. Industrial Medicine will provide pre-employment and annual examinations for employees handling asbestos-containing materials.
2. Safety Directors will encourage supervision to make random audits of asbestos handling activities to ensure the potential for overexposure is minimized.
3. Environmental Health Services will provide educational information, con duct exposure surveys as required and recommend what protective measure should be used.
4. Environmental Services will corrdinate the notification of the Texas Air Control Board as needed for demolition or renovation work involving asbestos materials.
5. Engineering and Purchasing will assist supervision through specifications and actively seeking and distributing information on asbestos substitutes.
Norvall Mears/ks
THE DOW CHEMICAL COtOTTTST'dY
Texas division FREEPORT. TEXAS 77541
September 6, 1972
MAINTKN AN CK FOH JiMKN
In order to obtain data on exposure levels during removal of asbestos-containing insulation, the Environmental Health Department must talce several samples, during removal, of each type or class of asbestos insulation. This data must be obtained and evaluated prior to December 1, 1972.
Most high temperature insulations (above 800F) installed
prior to August, 1970, should te suspected of containing
asbestos. Before removing this type material, the appro
priate Plant A or Plant B Insulation Foreman should be
advised cf the .job so that monitoring may be arranged as
required. This information car. most readily be conveyed
through Cynthia Cervenko, A636 for Plant A or Orville Smith
2581 for Plant B.
`
'
A complete revision of the ''Handbook for Handling Asbestos Materials" is attached; it defines the procedures and safe guards required for proper handling. It should be noted that precautions for sawing of transire (cement-asbestos board) are included.
All waste asbestos-containing material must be properly bagged and labeled for disposal by the Yard Department'. Labeling tags have been ordered (see attached sketch) but are not yet available. In the interim, attach n plain tag
ST05744 15
os a ttnch
F. B. Crouch
1V i 1 01 'S9
HANDBOOK FOR
HANDLING ASBESTOS MATERIAL
THE DOW CHEMICAL COMPANY TEXAS DIVISION
Maintenance Department Supporting Services
July 1972 Rev,
HANDBOOK DON HANDLING ACHES'1OH MATERIALS In do:-:
1. Purpose2. Safety 3. Use of Handbook 4. Safe Work Procedures
Fabrication of Asbestos Materials I-Nxing 0exent Containing Asbestos Handling and Storing AsbestosMaterials Sawing and Cutting by Hand Insulation Re.-.icvnl 5. Insula tor Safety Cnee): L`.i 6. Threshold Lir.it value
Page (s) 2 3 4
5 6 7 8 a 10 u
c/>
n
PURPOSE
The purpose of this handbook is to define safe handling procedures for asbestos materials used in the Texas Division. The .intent- is to control the exposure of employees to asbestos dust through the proper use of safe work procedures and by the sub stitution of non-asbestos containing materials.
Asbestos is widely used as structural wall board, insulation, and roofing material. Asbestos fibers are used as a mechanical reinforcing matrix in in sulation, roofing paper, certain piping systems, etc. However, Dow Engineering Specifications were revised to exclude asbestos-containing insulation prior to installation of Federal regulations controlling the use and handling of asbestos. Eventually, the use of asbestos will be eliminated as the ultimate solu tion to the problem.
The OSHA standards which became effective July 7, 1572, define the precautions required for asbestos handling and the allowable safe 'working limits.
Should a hazard exist, and these procedures appear insufficient, contact the superintendent of the Plant A or B Functional group?, for exceptions or variations.
These procedures will be reissued prior to 7 December J2 to incorporate revisions dictated by results obtained from the Division Monitoring Program.
so on -4
CD
r\
SAFETY
The health of those who broai.he asocslos cusi; may bo ssr: ous.1y affenttd. .{ei'nlts can be similar but more serious than t'r.oso caused vy the more common ly known materials such as silica and coal dust. This phenomena has been obsyved for many centuries. Current medical discoveries show Ltat handling of asbestos by s confirmed eica otto apcolcerM s espec ially hazardous. in tec area of potentially serious lung disorders. It is recommended that those persons handling asbestos rot smoke cigarettes in any quantity.
When working with mate; rids which contain a ah os tors fiber, care must be taken to eliminate as much loose dust as possible. Wetting, Isolating the work area, or other suitable procedures tc eliminate the dust hazard are absolutely necessary. The main problem areas will be in removal of ole, deteriorated in sulation and the sawing of Transite.
Respiratory protection, dust collectors, blowers, etc., will be mandatory where asbestos-containing material:: must be handled.
The two "nose and mouth" dust respirators which have been approved by the Safety department are: (l) MSA Dustfoe 77, Dow Stock No. 15-2*005, Cartridge No. 16-23775 > ord (2) Wilscr. Dust Hc-spirator, Dow Stock No. 15-25460, Cartridge Xo. 16-23790.
Disposal of asbestos will he in polyethylene bags. Dew Cfcock No. 15-05080 for large bag and 15-04170 through 15-04135 for small bags.
Ac required, special protective clothing such as cover alls, head covering and gloves will he provided. Such requirements will be dotermir.ec by the Division Moni toring Program.
rwo lockers will be provided, :o separated or isolated
as ::o prevent eentax-ji nation of the emu levee' s street clothes from his work lotres.
/iSbestei:-.-.-onlaminatc-d clotnL:w; snail he placed in labeled, polyethylene lugs fur r.-'.puco'.; -.0 the laundry.
oo TM< :=J ,:/1
USE 0I-' EOS
HANDLING ASBESTOS MATERIALS
The Safe Work Procedures outlined in this handbook are minimum requirement.::. for working with asbestos o on t a :i n 1 ng i::a tori a 1 a.
In some cases, job conditions may dictate more stringent requirements. Those could include com pletely wetting down the a .--a w:t tr. water when re moving old insulation, or completely isolating the work area with tarpaulins, etc. Specific require ments for each Job will be detailed on the"Insula tors Safety Check List."
Because Dow's Engineering Specifications have been re
vised to exclude use of asbestos-containing insulation.
most of the Safe V.rcrk Pros,
.r. this i ection of the
Manual will seldom be referred to for new i retaliations.
These procedures are to be used in conjunction with Plant safety Itu.'les, Maintenance Standard Safe '.fork Procedures for tho Area, and Safety Standards.
safe worn PF.ocEDMitr:
Sub j ec l: Shop Farr.! c:i :,.! or. U'i -i; Asbee Log Materials
M inimum Safety Equipment Requirements:
1. Side Shield Goggles mi:sc be worn.p Approved "Noce and Mr.:.tr." Dus;; Respirator must
be worn at all times. (See Pago 3)
.u There shall be a Dust Collecting System or. Power Equipment adequate to rcftovc- largo amounts of dust generated.
An Insulator Safety Check List is to be filled out prior to the job and properly approved. Turn in to supervisor at completion of job.
Special Precautions:
1. Do not breathe asbestos dust.
2. Do not operate equipment if provision, cannot be made to eliminate dust in a safe manner.
3. Normal precautions ir.ur-i so taken for working
with power equ.Lpnerh . (See specific Safe Work Procedure for Op Cl in doubt).
b. When cleaning out a res pi rator laud handl ins. PIvnt,V> \; * bags, coal, 1aool a shoe tos via st e ic lar.df ill.
i^.: Good houookoe ping As boo tos duct mu s n res if ano w ion
. 1 V. J ;
be practiced, . '..ho suofj
Keen all pa:-:: onus fabi-i f\ n *' r\fi !pe.ra
ooservo cu.mmurn st
away from ch-o- ores unless z\ :-v:uil rv.:r.er. ny.i have beer:
on -H
CO
c.n i
no
SAFE YObK ?-OSFU\iK?: Sub jee v : T-h ;< 1 ng Mi la 1 '.."nich Contains Acbesr.os
Minimum Ssi'ety jSqi;iprr.G:';: .L-quir-omcnts:
1. Side Shield Sogglos must : a worn.
2. Approved "Nose ana Mouth1' Putt hesnii'ater mu
be '.;orn at all tjnes.
Page 3)
a. An Insulator Safety Cheek List is to be fill cut prior to t.ne ;o;. ar.fi property approved. Turn ,::i to superviser at completion oi' job.
Special Precautions:
1. Do not breathe asbestos Gust.
2. V,'hen mixing whole sacks, do not eper. sacks and dump into open mixing tray. Moisten asbestos by adding water through a small hole in sack until danger of Gus\ is eliminated. Then the material can bo rec.ovod if necessary to complete
mixing operation ic dor.'red consistency.
3. Slipping or falling Is a hssaro to be considered when vjorkir.n around wet asbestos mud.
4. Back strains
handling containers of mined
mud are also a houord. A means cf har.dii.ng ck.l s
mixture may need to be provided, depending on
the elrcunstansos.
Keep all personnel not directly involved in the mixing operation ;r;;>v from -.-.he area unless ;;hey obsorve minimum so?.--:/ rocu.'rosier.to and navebeen cryori::oG of the uu'u-.rdrj involve::.
6 All contaminated
be wettsci, planeand sent to Ia:i:i
: oxoe, via>to, e to., i:hall ai.elc-d pclyethylene be.r.s
co
--t cto
Ol
4-~
IV> ho
SAFE WORK PROCEDURE
Subject: Handling and Storing Asbestos Materials
Minimum Safety Equipment Requirements:-
1. Side Shield Goggles must be worn.
2. Approved "Nose and Mouth" Dust Respirator must be worn at all times. (See Page 3)
3. An Insulator Safety Check List is to be filled out prior to the job and properly approved. Turn in to supervisor at completion of job.
Special Precautions:
1. Do not breathe aBbestos du3t.
2. Handle materials in such a manner as to minimize exposure to dust. Moisten material with water spray before removing from container if material will not be damaged.
3. Areas used to store asbestos containing materials should be-marked "Asbestos Material".
4. Cartons, boxes, etc., that have contained asbestos materials should be wetted, broken and placed in labeled polyethylene bags for disposal.
5. Good-housekeeping of shop areas is to be practiced. Clean up all loose dust on floor, machines, shelves, etc., by vacuuming. Wet down, place in labeled polyethylene bags and dispose of dust while damp. Notify the Yard Department to dispose by landfill while material is still damp.
SAFE WORK PROCEDURE
Subject: Sawing and Cutting by Hand
Minimum Safety Equipment Requirements:
1. Hard Hat must be worn.
2. Side Shield Goggles must be worn.
3. Approved "Nose and Mouth" Dust Respirator must be worn at all times. (See Page 3)
4. An Insulator Safety Check List is to be filled out prior to the job and properly approved. Turn in to supervisor at completion of job.
5. All other safety equipment which is required by job location must be used. (Read Area Safe Work Procedures.)
Special Precautions:
1. Do not breathe asbestos dust.
2. Wear the "Nose and Mouth" Dust Respirator when removing asbestos material from package, installing, or cutting.
3. Keep all personnel not directly involved in the operation away from the area unless they observe minimum safety requirements and have been apprised of the hazards Involved.
4. Special precautions shall be taken 'when using "Skil-Saw" for sawing asbestos materials. To eliminate dust hazards and protect all people in the area, an air operated saw shall be used and the material shall be flooded with water.
5. If water will damage the material, a hand saw shall be used and sawdust collected with a portable vacuum whenever possible. If site work prohibits use of a vacuum pick-up, cuts should be made directly over a collection box or polyethylene bag.
6. All contaminated bags, boxes, waste, etc. shall be wetted, placed in labeled polyethylene bags and sent to-landfill.
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SAFE WORK PROCEDURE
Subject: Insulation Removal
Minimum Safety Equipment Requirements:
1. Hard Hat must be worn.
2. Side Shield Goggles must be worn.
3. Approved "Nose and Mouth" Dust Respirator must be worn at all times. (See Page 3)
4. An Insulator Safety Check List is to be filled out prior to the job ar.d properly approved. Turn in to supervisor at completion of Job.
5. All other safety equipment which is required by Job location must be used. (Read Area Safe Work Procedure.)
Special Precautions:
1. Do not breathe asbestos dust.
2. Hazards from asbestos dust that falls, blows or may be scattered throughout the area must be eliminated,
3. Keep all personnel not directly involved in the insulation removal operation away from the area unless they observe minimum safety requirements and have been apprised of the hazards involved.
4. Use water to wet down the insulation before and during removal.
5. Seal all material in labeled polyethylene bags as removed. The Yard Department is to be notified for disposal at landfill.
INSULATOR SAFETY CHECK LIST
JOB DESCRIPTION:
DATE
LOCATION
AREA
Safe Work Permit Recei vod
YES NO LJ U
II. ASEESTOS WORK
YES NO
1. Handbook for Handling ;
j
Asbestos Materials Used?-----
Area Safe Work Procedure Known
Nearest Phone
4 Nearest Eyebath and Safety Shower _______
e; Job Site in Safe Condition
.6 Is Pipe or Equipment
Safe to Work On?
L.J , i
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2. Signs and/or Barricades1'--11 Cl Up to 'Warn Others y
3. Has Disposal of Debris --1 1.7.7 3een Arranged ?
4. Is Water Needed to Control Dust ?
5. Stencil on Job to DenotC--J I Materials Used ?
6. Have all Involved
1 ~'j
Personnel Been Informed ?
7. Are Corrosive Chemicals Involved?
a. Can lines or equipment be drained?
.8 Is Adjacent Piping and Equipment Safe
9. Rea Tags Needed?
1 . Burn Hazards Present?
.11 Craftsmen Lined Up With Cheek List?
Special Safety Equipment Required:
Coveralls Chemical Goggles Face Shield Acid Hood Air Mask
GO ---\
o CJ1
Dust Respirator
Rubber Gloves
.ir-
Rubber Boots Slicker Coat
(NO CT
Slicker Pants
Safety Belt
Hearing Protection
Other: Specify
Special Hazards
Personnel on Job (Name) Exposure Time-Hrs.
Special Safety Precautions
Checked and Approved By:
Supt. Foreman C rev,-leader Craftsman
DATE: 1C
THRESHOLD LIMIT VALUE
No employee shall be exposed at any time to air borne concentrations of asbestos fibers in excess of 10 fibers# longer than 5 micrometers, per cubic centimeter of air. The eight hour time-weighted average shall not exceed five (b) fibers per cubic centimeter.*
In order to assure compliance with these limits., the Environmental Health Group will make random samples. When special field testing is desired, call Environmental Health at. ?'3ft-2121.
In order to keep asbestos dust concentration within the proper limits, any dusty conditions connected with the handling of asbestos materials must be kept to an absolute minimum. This must be done as out lined in the previous Safe Work Procedures by v/etting down the area, pre-soalcing the material, or vacuuming the material as It is cut. Each individual job should be planned with this uppermost in mind.
co --A
* Effective 1 July 1976, this limited Is reduced from five (p) to two (2; fibers per cubic centimeter.
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DOW CHEMICAL U.S.A.
50983____________________________________________________________
Texas division FREEPORT, TEXAS 77541
ENVIRONMENTAL HEALTH REPORT
EVALUATION OF ASBESTOS EXPOSURES, DOW INDUSTRIAL SERVICES, HIGHWAY 332
Fll E NO. M-152 .
niTF September 10, 1973
.author
Silverthorne
L. 0. Trahan
CHFCIfFn
(R.c? rS&L&t*
DATE--------------------_______________________________
Summary
The employees exposure Co asbestos fibers were evaluated during the cathode cleaning operations at Dow Industrial Services. The time weighted average and peak exposures to asbestos fibers are within acceptable levels.
07
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cn
Distribution
L. A. Little File
AN OPERATING UNIT OF THE DOW CHEMICAL. COMPANY
File No. M-152
-2-
ST0684752
PROBLEM
Industrial Hygiene was asked to evaluate the exposure of Dow Industrial Service employees to asbestos fibers during the cathode cleaning operations.
CONCLUSIONS
(1) The employees time-weighted average and peak exposures to asbestos fibers are within acceptable levels.
(2) The entire cathode cleaning shed is covered with wet asbestos.
(3) Asbestos fiber levels in the workers clothes were in the 0.09 to 0.16 fibers/ml range.
RECOMMENDATIONS
(1) Wash down walls and floor of cathode cleaning shed daily.
(2) Showering should be compulsory at the end of the work day for those employees who work at the cathode cleaning shed.
(3) Employees should have clean work clothes daily.
PRESENTATION OF DATA
Table I shows the operators exposure to asbestos fibers based on an eight hour day when the cathode cleaning operation is in progress. The time weighted average and peak exposures are within acceptable levels based on the present standard.
Table A shows the results of the sample analyses for the various cathode cleaning operation. The highest asbestos fiber concentra tion, up to .166 fibers/ml, were found in the worker's clothes.
SAMPLE AND ANALYSIS
Breathing zone and general area air samples were collected on 47 ram diameter (.8 micron pore size) membrane filters at a sample rate of about 2.0 1pm. The fibers on the filters were counted by the standard phase-contrast microscopy technique at 450 magnification by the Texas Division Microscopy Laboratory.
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50983
DOW CHEMICAL U.S.A.
TEXAS DIVISION FREEPORT, TEXAS 77541
ENVIRONMENTAL HEALTH REPORT
RE-EVALUATION OF ASBESTOS EXPOSURES, CELL SERVICE, A-1323 AND A-1022 BUILDING
FILE NO.. A10-196 DATE September 12, 1973
R.L. Sllverthorne LT G "Trahan--------------B. S. Horvath
CHECKED
DATE
Summary
The cell service employees exposure to asbestos fibers were re evaluated during the diaphragm drawing operations. The timeweighted average and peak exposures to asbestos fibers are within acceptable levels, though the peak exposures could approach the maximum allowable concentration. The employees should continue to wear respiratory protection during the weighing and dumping of asbestos into the drawing vat.
Attached are recommendations that could reduce exposure to airborne asbestos to employees even more than the precautions already taken.
2nS08S01S-
Distribution
J. M. Hart A-1003 S. F. Edquist A-1201 File
AN OPERATING UNIT OF THE DOW CHEMICAL COMPANY
File No. A10-196
-2-
ST0580543
PROBLEM
Industrial Hygiene was asked to re-evaluate the exposures of Cell Service employees to asbestos fibers during the diaphragm drawing operations.
CONCLUSIONS
(1) The employees time-weighted average and peak exposures to asbestos fibers are within acceptable levels.
(2) During the weighing and dumping of asbestos, peak concentra tions could approach the maximum allowable concentration for short term exposure. The men working around the pulling tank when asbestos bags are handled and dumped into the vat should continue to wear respiratory protection.
RECOMMENDATIONS
(1) Empty asbestos bags should be stored in a plastic bag and sealed before disposal.
(2) Employees who work regularly with asbestos should have clean work clothes daily. (Work clothes are not to be takn home for laundering).
(3) Continue the work practice of wearing respiratory protection whenever asbestos is handled.
(4) Showering should be compulsory at the end of the work day for those employees with significant exposures.
(5) Engineering methods to be utilized to eliminate asbestos exposure to employees.
PRESENTATION OF DATA
Table I, II, and III shows the operators exposure to asbestos fibers based on an 8 hour day when the drawing operation is in progress at A-1322 and A-1022. His time-weighted average and peak exposures were within acceptable levels based on the present standard.
Table A shows the results of the sample analyses for the various Cell Services operations. The highest asbestos fiber concentra tion, up to 5.86 fibers/ml, were found during the weighing and rfr-
c
File No. A10-196
(. -3-
PRESENTATION OF DATA (continued)
dumping of asbestos. Because of the variability in the asbestos handling procedures (and in the fiber counting technique) the operator peak exposures could exceed the allowable ceiling concentration. The men working around the drawing vat, during the handling of dry asbestos, should wear respiratory protection.
Asbestos fiber levels exceeding 0.5 fibers/ml were found only in the immediate area of the drawing vat. The exposures of the other employees working in the building were well within acceptable levels. Their TWA* exposure would be in the .01 to .03 fibers/ml range.
SAMPLE AND ANALYSIS
Breathing zone and general area air samples were collected on 47 mm diameter (.8 micron pore size) membrane filters at a sample rate of about 2.0 Lpm. The fibers on the filters were counted by the standard phase - contrast microscopy technique at 450 magnifica tion by the Texas Division Microscopy Laboratory.
$T0580544
* Time-Weighted Average (TWA) - The average "exposure of asbestos fibers to employees during an eight hour work day.
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MATERIAL
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MATERIAL k .
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PROCESS /C <C-//
EQUIPMENT NUMRER
TYPE OP EQUIPMENT
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DATE 6-7-73
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PLOW INDICATOR SETTING SAMPLE PLOW RATE OUTMOe TEMP.
INSIOE TEMP.
Pvyypi____ ____ _____
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Sl*Y\*CiSV\S . _____(2^ beJ T___ -2.S~> (Is)
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ST058,05,53
Ml 0-1M79 PIIETU II H.S.A. U-(S
CRI NUMBER
I ip & D REPORT
L.r*
V blob
DOW CHEMICAL U.S.A.
RESTRICTED: for us within Th* Dew Chvmico! Company
C A.n TMC*. "
NBH2.I2-28-I(2-5) qa'E -ssuet:
SeDteraber 24, 1973
*c:ofc`: nv
r.yviaen
DIG Chemical Biology Research
t` f.e
377 1 9080003
ASBESTOS EXPOSURES DURING MAINTENANCE, DEMOLITION AND TRANSITS FABRI i CATION, 500. 580, XI99, 349, X376, 150 and 596 BUILDINGS
AL'SOI' 1- biiJSA ruMc. S
M. F. Stevenson JLjL
H. Flores
ktV'trtEC 5 StCNAT'.^E
H. R. Hcvle
f-^S-73 /*&
DESCRIPTIVE SUMMARY WITH CONCLUSIONS:
(Include in this saoce rf?/tic*s to date books, end to *arlir rclati'J reports, patents and publications.!
Air samples to determine asbestos exposures were taken during various construction and demolition operations. The outdoor demolition work and indoor pipe stripping work at X199, X376 and 349 Building showed the lowest asbestos counts of the three areas sampled. The mainten ance work at 500 and 580 Buildings approached the maximum allowable concentration. Transite fabrication at 596 and 150 Buildings approached and exceeded the maximum allowable concentration of 10 fibers per milliter (fibers/ml).
Anyone working in the immediate vicinity of such jobs should use .approved respiratory protection.
STOOG-0982
DISTRIBUTION:
R. R. Langner, Industrial Eygiene Services, 607 Building E. B. Holder, M.D., Medical Department, 6C7 Building M.Xelyman, Safety Department, 400 Building B.E, Harmon. Safety Department, 572 Building H. a. Hoyle, Industrial Eygiene Section, 1701 Building L. L. Hagen, Power Maintenance, 500 Building V . Gunther, Power Maintenance, 500 Building M. J. Burrell, 572 Building R. B. Willz.air.son, 572 Building R. P. Brentin, Foam Products Research, 657 Building M. G. Bussey, Foam Products Research, 657 Building Central Report Index (5), 566 Building
S. -
41
1 ST0000983
PROBLEM The industrial Hygiene Section of DIG Chemical Biology Research was asked to evaluate asbestos exposures during maintenance, demolition and transite fabrication at various buildings in the Midland Division.
CONCLUSIONS 1- Exposure to asbestos fibers was greatest during transite fabrication. Levels recorded at 596 and 150 Buildings approached and exceeded the maximum allowable concentration of 10 fibers/ml.
2. Exposure to asbestos fibers approached the maximum allow able concentration at 500 and 530 Buildings during the removal of insulation from boilers and crackers.
3. Asbestos exposures were minimal while removing covering from pipes at X199, X376 and 349 Euildings.4
4. Wetting down and careful handling while removing asbestos insulation reduces airborne asbestos fiber concentrations (See Table 1 and 2).
-2-
S T 0 0 0-09 8 U
RECOMMENDATIONS 1. The use of procedures & equipment required by Occupational Safety and Health Act and Environmental Protection Agency re gulations such as signs, roped off areas, dust tight bags and approved respiracors should be continued.
2. No friable asbestos debris should be dropped or thrown to the ground or to any floor below for any building or structure 50 feet or greater in height. This debris should be trans ported to the ground via dust tight chutes or containers. (See Federal Register, Volume 38, Number 65, 61.22 - EPA Emroision Standards) .
3. When removing asbestos in an outdoor environment the section to be removed should be kept wet until final dis posal has been accomplished.
4. Workers working down wind from an asbestos stripping operation should be advised to wear respiratory protection until air samples are taken to prove otherwise.
5. Sawing equipment used Lr. fabricating transite should be equipped with dust control devices. A wet cutting blade, local exhaust for the cutting area or a combination of the
-3-
ST0000985
-4-
above two methods should be considered as possible engineer: control methods. Air sampling will be required to assure satisfactory control of asbestos fibers.
6. A possible reduction in the speed of the cutting blades when fabricating transite should also be considered as a viable method in the reduction of airborne dust.
DISCUSSION As per Federal Register, Volume 37, Number 202; paragraph 1910.93a, every employer shall monitor the air breathed by workmen who might be exposed to asbestos to assure that the concentration of asbestos fibers is within accepted limits. The areas monitored thus far include demolition of buildings removal of asbestos insulation from pipes, boilers and crack ers (maintenance purposes) and transitsfabrications.
1. Demolittcr.. Operations - Asbestos was US ed extensively in cld fcu tidings as an. insulating maternal f. tanks and pipes. Aebes t is is a fibrous material and tends tc become airborne when buildings are demolished. Therefore, monitoring for asbestos at X199 and X376 Buildings was done in May of 1973, by the Industrial Hygiene Section of DIG Chemical Biology
ST0000986
-5-
Research. Breathing zone samples and area samples were obtained. These readings ranged from 0.11 to 0.48 fibers/ ni. (See Table 3} The ground was damp and equipment ranging from small bulldozers to large cranes was being used. Small pieces of flaky asbestos particles were seen on the ground and entangled in parts of the steel structures. A transite sample was obtained for analysis to determine the percent asbestos and related elements (See Table 4). None of the precuationary measures required by regulation was in evidence at the time of sampling.
Removing asbestos insulation from pipes can present high exposure possibilities. At 349 Building, breathing zone samples were taken while removing insulation, the results ranged from 0.3 to 2.3 fibers/ral. The men at this operation were handling the asbestos carefully. They were using dust tight bags to contain the insulation as it was removed. Pipes had been wet down earlier that morning.. The results indicate that a workers exposure can be controlled. The majority of respirators worn were net Dow or U. S. Bureau of Mines approve and further education of the contractors is needed.
2. Maintenance Operations - Here, as above, removing asbestos insulation was the primary concern. At 500 Building asbestos was being removed from a boiler. It was an indoor job with a
S T 000098 7
-o-
strong wind coining from the east entrance and blowing northerly. No signs or ropes were in evidence. Disposable respirators were worn but were not the type recommenced. Recommended types of respirators and filters to be used while working with asbestos are: Mine Safety Appliance Ultra Filter respirator with Cartridge "H" ; Amiercan Optical with respirator "3M 2304" with RS7 cartridge; 3m Brand., No. 371C respirator, disposable. Disposal of asbestos was improper no dust tight bags were used at all. Asbestos removal was done in two different ways. First, the asbestos was shoveled into a wheel barrow and emptied into an open dumpster. Second, the asbestos was shoveled into the running water used to carry fly ash. etc., into holding areas. See Table 5 for results of 500 Building sampling.
At 580 Building, "L" cracker, an outdoor asbestos stripping operation was going on. A strong wind was blowing n.orthwesterl toward other maintenance workers not envoived in asbestos removal. Precautionary measures oaken included all but the wetting down process. Samples were taker, prior to and after the work area was wet down (See Table 1). The operator was told that he should wear his respirator whenever working in this area and that samples would be taken. The results ranged from 1.5 to 9.1 fibers/ml.
ST0000988
3 . Transite Fabrication - Transite is a heat resistant substance used at Dow for reacccr enclosures, etc. This fabricating substance is known to contain about 30 to 40% chrysotile, one of six different types of asbestos (See Table 4 and AL#060798).
Prior to the installation of transite the material must be cut to proper size. Sawing transite creates a very dusty situation not only for those doing the cutting but for others working in the immediate area. '
Samples were obtained at 595 and 150 Buildings. At 150 Building results ranged from 32 to 42 fibers/ml. The work done here was in a partially enclosed area. At 596 Building sample results ranged from 0.1 to 11.1 fibers/ral of air sampled. Tne samples taker, here were primarily outdoors and brisk winds tended to disperse the dust. (Tables 5 and 7}
SAMPLING AND ANALYSIS Breaching zone and general area air samples were colleccsd by two different methods:
1. For breathing zone samples personnel sampling pumps with millipore filter cassettes (0.S micron pore size) were used at sample rates of about 2 liters per minute.
STOOOO989
-8-
2. General area air samples were obtained by using personnel pumps and cast pumps. Filters used with the gast pumps were 47 mn in diameter and 0.8 micron pore size. Sampling rate of about 23 liters per minute was obtained by use of a No. 5 limited orifice.
Fibers on the filters were counted by standard phase contrast microscopy technique at 450 magnification by the Midland Division Microscopy Laboratory (ALrrf64-788, 65-073, 059824, 059837 and AAT73-271) .
Bulk samples were obtained of asbestos and transite to determine content by percent composition (AL#060798, AL06078S). These results were obtained by x-ray diffraction analysis.
: ST0000990
TABLE 1 Stripping Asbestos From "L" Cracker. 530 Building
Sample Number
________________Operation
1 Picking up loose asbestos (wet)
2 Picking up loose asbestos (wet)
3 Stripping asbestos from Cracker (not wet)
4 Stripping asbestos from Cracker (not wet)
5 Stripping asbestos from Cracker (wet)
6 Crane Area - down wind
Asbestos Concentration (fibers/ml)
1.8
1.5
8.9
9.1
6.2
4.S
NOTE:. Sample 6 was a general area sample and sample 3 was loose dust picked up off the crane. All others are breathing zone samples.
-9-
ST000099I
TABLE 2 Removing Asbestos From Pipes, 349 Building
Sample Number
Operation
1 Removing insulation & bagging asbestos
2 Removing pipe covering 3 General area 4 Removing insulation & bagging 5 Removing insulation from pipes 6 General area
Asbestos Concentration
(fibers/ml)
0.7 2.3 0.2 L. 5 0.S 0.3
NOTE: Ereathing zone samples except: where indicated.
4
-10-
ST0000952
TABLE 3
Demolition of Old Buildings with Asbestos Insulation on Pices., Reactors and Transite Wails: X199 & 376 Buildings
Sample Number
ODeration
X376 Building 7 Area sample 8 Outside cabe of crane
Asbestos Concentration
(fibers/ml)
0.43 0.29
XI99 Buildinc
9 Man operating catipillae (loading truck with debris)
10 Man operating small utility bull dozer - pushing debris into stacks
11 Man o perating crane
12 Area sample, approximately 100 feet north of buridinc - down wind
0.18 0.12 0.11
0.13
-11-
S TO 0 0 0 993
TAELS 4
Transits Sample From X375 Building - Sent to X-ray Diffraction to Determine Asbestos Concent and Other Crystalline Materials
Substance Found
Chrysotite Calcite {CaC03) Vaterite (CaCO^) Quartz Noncrystalline
Percent
30-40 10-20 15-25
15 5-15
Range of percent was confirmed by removing soluable car bonates (caicite & vaterite) and rerunning insoluable residue
A loose dust sample was collected at 530 Building from crane microscopic examination indicated that the dust is probably araosito, one of the six different types of asbestos present.
-12-
ST00-OO9-94
TABLE 5 Stripping Asbestos From #14 Eoiler, 500 Building
Sample Number
________________Operation__________________
Asbe stos Concentration
(f ibers/ml)
o
CD
1 Pulling asbestos block insulation from boiler
2 Pulling asbestos block insulation from boiler
6.0
3 Area sample, approximately 6 feet from work area
0.2
4 Pulling asbestos from boiler
1.3
5 Picking up loose asbestos
0.7
5 Picking up & emptying into derr.pscers
4.5
-t> Area sample, approximately 2C feet
from work area but down wind from
craft
1.0
8 ' Area sample approximately 8 feet G Pulling asbestos from bcil-r
<0.1 E. 9
0 Area sample approxirately 8 feet from work area
0.1
-13-
S 1*0000995
TABLE 6 Fabrication, of Transite, 556 Building
Sample Number
Operation
Cutting transite with rotary saw
Asbestos Concentration {Fibers/ral)
9.7
Man installing transite on platform
1.6
Background around doorway
0.1
Measuring transite board ar.d cutting with rotary saw
11.1
Man installing panals, occasionally drilling screw holes
1.2
General area, breathing zone height, around doorway
1.3
NOTE: All samples are in the breathing zone
ST 0000996
TABLE 7 Transite Fabrication, 150 Building
Sample Number
1 2
3
Operation Cutting transite with rotary saw
Man standing to immediate right of operating saw
Man standing to left of saw-- holding board down
Asbestos Concentration
(Fibers/ml) 40.7
32.0
42.5
NOTE: All samples were taken in the breathing zone
50983
DOW CHEMICAL U.S.A.
TEXAS DIVISION FREEPORT. TEXAS 77541
ENVIRONMENTAL HEALTH REPORT
EVALUATION OF ASBESTOS EXPOSURE TO INSULATORS AT GLYCOL "A"
FILE NO.. A18-237 mTF November 21. 1973 author --SiLverfhorae
CHECKED
///z//7S-
Summary
Contractor insulator exposure to asbestos fibers were evaluated during the removal of insulation on two columns at Glycol "A". The timeweighted average (the average exposure of asbestos fibers to employees during an eight hour work day) and peak exposures to asbestos fibers are within acceptable levels, although the peak exposures could approach maximum allowable concentrations due to the variability in the asbestos handling procedures. The employees should continue to wear respiratory protection during the handling of asbestos, and every effort should be made to wet down the asbestos insulation before and during removal.
CD CD
Distribution
F. A. Newman A-510 /File
CD id
AN OPERATING UNIT OF THE DOW CHEMICAL COMPANY
0 1 IS I001S
File No. A18-237
-2-
INTRODUCTION
Environmental Health Services was asked to evaluate the exposure of Insulators to asbestos fibers during the removal of asbestos insulation from two reaction towers at Glycol "A".
METHODOLOGY
Breathing zone and general area air samples were collected on 47 mm-diameter(.8 micron pore size) membrane filters at a sample rate of about 2.0 LPM. The air pumps used were M.S.A. permissible portable personnel pumps. The fibers on the filters were counted by the standard phase-contrast microscopy technique at 450 magnifi cation by the Texas Division Microscopy Laboratory.
DISCUSSION
Table A shows the insulator exposures to asbestos fibers based on an eight hour work day when insulation is being removed from reaction towers. His time weighted average and peak exposure are within acceptable levels based on the present OSHA standard.
Table B shows the results of the sample analyses for the various Insulator operations. The highest asbestos fiber concentration, up to 1.29 fibers/ml, were found during the actual removal of insulation by the employee. Because of the variability in the asbestos handling procedures the employee peak exposures could exceed the allowable ceiling concentration.-
CONCLUSION
1. The employees time weighted average and peak exposures to asbestos fibers are within acceptable levels.
RECOMMENDATION
1. Ashestos insulation should be stored in plastic bags, tagged and sealed for disposal.
2. Employees who work regularly with asbestos should have clean work clothes daily. (Work clothes should not be taken home for laundering).
T
4 File No. A18-237
-3-
RECOMMENDATIONS (continued)
3. Continue the work practice of wearing respiratory protection whenever asbestos is handled.
4. Employees with significant exposure should shower at the end of the work day.
5. Water should be used to wet down the insulation before and during the dismantling operation. This will reduce the possibility of asbestos fibers becoming air borne.
6. Environmental measurements should be made annually to determine the adequacy of precautions taken.
7. The contractor employer should be familiar with Subpart G, section 1910.93a, of the Federal Register.
ST 001511 I
EHS RLS/bbs 11-21-73
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ST0028264
SAFETY AND LOSS PREVENTION MANUAL
FOR CONTRACTORS
THE DOW CHEMICAL COMPANY
ENGINEERING & CONSTRUCTION SERVICES NOVEMBER 1973
ST0028265
SAFETY AND LOSS PREVENTION MANUAL
FOR CONTRACTORS
"It is the objective of Engineering and Construction Services to establish and maintain an active, successful accident prevention program that will ultimately result in top safety performance by con tractors doing work for The Dow Chemical Com pany."
THE DOW CHEMICAL COMPANY
ENGINEERING & CONSTRUCTION SERVICES NOVEMBER 1973
ST0028266
This manual supersedes Safety and Loss Preven tion Manual for Contractors dated February, 1970.
SAFETY MANUAL FOR CONTRACTORS INDEX
Safety Rules
Introduction
1 General Safety Rules 2 Emergency Procedures 3 First Aid--lnjuries--Reports 4 Individual Action 5 Vehicles and Traffic 6 Protective Equipment and Clothing 7 Fire Protection 8 Machinery, Tools and Equipment 9 Ladders and Scaffolds 10 Danger, Warning and Caution Tags 11 Safe Work Permits 12 Excavations, Floor Openings, Barricades 13 Radiation 14 Demolition
Paso
1 4 5 7 8 10 12 14 21 26 28 30 31 32
ST0023267
ST0028268
INTRODUCTION
This safety manual contains the minimum safety rules and procedures for per formance of work by contractors and their subcontractors as required by Engineering and Construction Services, The Dow Chemical Company, for any division, subsidiary or affiliate, hereinafter referred to as "owner." This manual will apply at all Engineering and Construction Services project locations unless the owner has an existing set of safety rules specifically for contractors. Exceptions to this manual, or any part thereof, will be agreed upon prior to starting any field work. The owner will be represented on con struction as defined in the contract and hereinafter referred to as "owner's representative."
Contractor assumes and has the full responsibility and liability for the safety of its agents, servants and employees and for the compliance of its subcontrac tors and anything contained herein does not relieve the contractor of such responsibility or liability.
Safety rules and procedures are an integral part of each contract and must be carried out fully, as any other specification for the job. The contractor will be held responsible for his subcontractors conforming with these safety rules and procedures. Any exception to the rules set forth herein, during the course of any project, must have prior written authorization from the owner's representative.
Contractors and contractor supervision unable or unwilling to secure per sonnel performance in keeping with these rules will not be acceptable as supervisors. Contractor employees who exhibit a poor attitude toward safe work and safety procedures will not be acceptable. Employees leaving a job due to safety violations will not be allowed to return to any owner's work without proper authorization from the owner. The contractor's safety record will be one criteria used to judge his qualifications for bidding.
In addition to the rules set forth herein, contractors working in or near an ex isting operating facility must be cognizant of and conform to owner's safety rules for that area and any federal, state or local laws governing.
Should any procedure set forth herein conflict with applicable federal, state or local laws, the latter will apply
ST0020269
1.0 GENERAL SAFETY RULES
1.1 The contractor shall actively and adequately promote safe working per formances on the part of his employees. Heshallparticipatem activities to this end, such as safety organizations, incentive award programs, contractorowner programs, etc. It is expected that each contractor will conduct his own safety programs to best suit his particular needs.
1.1.1 American Standards Association, Z-16.1 Standard, "Recording and Measuring Work Injury Experience," shall be used as a guide to classify contractor injuries.
1.2 Prior to starting any field work on each job. the owner's representative will conduct a prejob safety conference with an authorized representative of the contractor, a manufacturing representative, when available, available subcontractor's representatives and owner's Safety Department represen tative, when available. At this time, the nature of any chemical hazards or special safety rules for the area will be reviewed with the manufacturing representative and the contractor will be provided with printed copies of area rules where applicable. The "Prejob Safety Check Sheet" form (see sample) will be prepared by the owner's representative and a copy furnished to the contractor.
1.3 An effective system of indoctrination and education of employees in safety and loss prevention shall be provided by each contractor. Contractors shall inform all their employees of all safety rules and all safety procedures before working in an owner's plant.
1.3.1 Contractors shall inform all of their employees of the location and the use of nearest safety shower, eye bath and emergency equipment such as gas masks, fire extinguishers, and fire blankets.
1.4 Contractors shall use a regular system of work inspection to detect and correct hazardous conditions, safety rule violations and unsafe working con ditions. These safety inspections shall be reported to owner's representative in writing each week.
1.4.1 Orderliness is a basic requirement for all jobs and must be main tained at all times. Special attention must be given to maintaining clear walkways and roadways, removal of trash, removal of slipping and trip ping hazards and proper storage of materials. Contractors must make every effort to keep mud, slush or other slippery substances off of plant roads. In cases where this cannot be avoided, contractors must clean the roadways immediately.
1.5 Temporary buildings and material storage areas shall be set up as neatly as possible to present an orderly appearance.
1.5.1 Temporary building shall be sheeted with noncombustible material, such as transite or metal siding and roof, and each must be identified with the contractor's name.
1.5.2 Metal buildings served with electricity must have the skin of the building properly grounded as well as the service entrance switch.
-1-
ST0020270
90V3* HE V. C
JOB:___________________
CONSTRUCTION PRE-JOB SAFETY CHECK SHEET
JOB or C 0 NUMBER
CONTRACTOR
1. Standard Emergency signals fully understood? 2. Contractor responsibility m time of emergency understood7 3. Fire and ambulance telephone numbers known7 4. Location of available medical facilities known7
5. Areos for possible evacuation designated 7 6. Fire protection requirements known ond plans mode for provi sion of
adequate equipment? 7. Special safety rules and signals for this area known?
lOwner will provide written special rules where applicable.)
8. Nature of chemical or special hazards for area reviewed with Manufacturing Representative?
9. Special safety equipment for this orea known7
10. Safety Showers ond Eye Wash locations known7 11. Safe work permit understood? 'Designated placets) to obtain known7' 12. Name of individual!s) to issue safe work permit_______ ___________________
13. Red Tog rule understood? 14. Smoking area designated7
15. Contractor scaffold rules known7 16. Crane inspection and critical lift procedure understood7
17. Unfired pressure vessel test procedure understood7 18. Do you have o copy of and understand "Safety & Loss Prevention Mu -nl
for Contractors"? 19. Contractor assumes responsibility for and control of their vendors entering
the plant for compliance with plant safety rules ond regulations7
20. Are your subcontractors awore of rules and procedures7
REMARKS: _________________________________________________________________________
*
>*
1
DATE:. BLOCK:
Yes
Yes Yes Yes Yes Yes
N.A. N.A. nN.A.
N.A.
N.A. n< d'
N.A.
Yes
N.A.
Yes
N.A.
` Yes Yes nYes
aYes
Yes
Yes
Yes
cYes
N.A.
N.A. N.A.
cN.A.
-N.A.
N.A. N.A. N.A. N.A.
Yes
N.A.
Yes Yes
N.A. N.A.
Contractor Representative Owner's Representative Manufacturing Representative Owner's Safety Representative
Date Date Date Date
Subcontractor Subcontractor Subcontractor -2- Subcontractor
Dote Date Date Date
ST002827 I
1.6 Contractors must furnish trash containers made of metal, each with metal covers kept in place. 1.7 Contractors must report to the owner s representative, by name, those employees discharged for safety rule infractions. 1.8 Contractors shall maintain continuous safety planning to cover jobs where circumstances have changed and new hazards require new controls.
-3-
ST0028272
2.0 EMERGENCY PROCEDURES
2.1 Contractors must inform their employees of existing plant procedures for first aid and ambulance calls. If none exist, the contractor shall submit to the owner's representative prior to starting work, an outline of the procedure to be followed.
2.2 In the event of an explosion or fire, contractor personnel working in the area affected must observe the following rules.
2.2.1 Shut down all equipment in operation and leave the area at once.
2.2.2 Report to your company field office immediately, in person or by phone.
2.2.3 DO NOT re-enter the area until authorized by the owner's representative.
2.2.4 The contractor shall notify the owner's representative in person or by telephone as soon as possible that all employees in the area are ac counted for or that specific employees cannot be accounted for.
2.3 If operating a motor vehicle in an affected area, turn off engine, get out of the vehicle, and be prepared to leave the area if necessary. Motor vehicles, other than emergency units, must not be driven into an area downwind of a gas release. Barricades across plant roads must be honored by all vehicles at all times.
2.4 Contractors shall inform theiremployees of pertinent emergency signals and procedures for the area m which they work. If none exist, the contractor shall outline and inform employees of steps to be taken in the event of disaster emergencies that could arise.
ST0028273
3.0 FIRST AID - INJURIES - REPORTS
3.1 The owner s representative shall be notified immediately in the event of any death, occupational disease, disabling injury or potentially significant in jury to a contractor employee (whether or not it is determined that "lost time" will be involved) while at work on the owner's job.
3.1.1 The contractor must thoroughly investigate, determine and report ail details of an accident and cooperate with the owner's inspec tion teams. 3.1.2 A written report must be submitted on every injury requiring medical treatment of any kind, to the owner's representative on the job, no later than 1O00 a.m. of the day following the injury. Also any near miss, potentially serious or hazardous condition that occurs, must be reported in the same manner, although no injury to personnel may be in volved. Forms for these reports, "Notice of Contractor Accident and Property Loss" are available through the owner's representative (see sample). 3.1.3 All fires must be reported regardless of duration or extent. 3.2 Employees must report any injury to their immediate supervisor even though it may be considered slight. 3.2.1 The contractor will assure that all injured personnel report to a recognized medical facility. 3.2.2 In the event of any serious injury, an ambulance MUST be called. 3.2.3 In the event of accidents, ambulance run, etc., contractors must exert all possible effort to keep onlookers from the scene. The only per sonnel required in such areas are those directly engaged in assisting in the emergency. 3.3 Employees must not attempt to remove foreign material from the eyes, except by washing with water. If foreign materials get in the eye, the eye must be washed immediately with running water, preferably at an eyewash station and the washing continued uninterrupted for at least fifteen minutes. It is vital that the injured employee and others who are able to help him make sure that thorough and complete washing of the eye is accomplished. 3.4 If chemicals come in contact with the body, the affected parts must be washed with running water for at least fifteen minutes. To make sure that ade quate washing is accomplished, shoes and clothing covering affected parts must be removed. The owner's representative must be consulted before reuse of clothing and shoes that may have been contaminated.
-5-
304*920 REV C
notice of contractor accident or property loss
THIS NOTICE tO BE Su QM iTTEO By c ON TPA 7
TO TmE OWN C W i<EpWE5rN '* r . L AS '-OON AS POSSIBLE. BUT SCT L*TER
THAN 10 00 A.M. THE day AFTER ANY 'NJURv REQUIRING MEOiOL TREATMENT (jF A N v K NO. OR POR ANY POTENT A L >
SERIOUS incident or HAZARDOUS conc.-ion CCCUPRINO. H'HOliCH nc -n,..v
NVOLVED.
CONTRACTOR_______________________________________ _____________
A.M.
p_ 0. ;
DATE TIME___________________ ________ P.M.
SUB CONTRACTOR _ i_QC A T ION___
NAME OF INJURED_ CRAFT_______________ EXTENT OF INJURY.
_______________________ AGE CLOCK NUMBER
WHERE TREATED IS THIS A DISABLING INJURY YES
WHAT HAPPENED
NO INDEFINITE
GO
oo
ro co r\> --i
XT
CAUSE
CORRECTIVE ACTION TAKEN
SAFETY INVESTIGATION MADE BY
r o*
GCNCPAl rcPfvA*.
PttIUE CONTPACTOP 1UPt.
DATE DATE
OFPH S ( 4 T A f VI no* coiistpuc * on supt
DATE___________________________________________________
-fi-
DATE DATE
__ DATE
ST002C275
4.0 INDIVIDUAL ACTION
4.1 Horseplay in any form is not allowed. 4.2 Running in the job site must be avoided except in case of an emergency. 4.3 Personnel must not climb through, under, over, or between railroad cars of a train except in the performance of assigned duties. 4.4 Personnel must not make inoperative or operate safety devices such as relief valves, deluge valves, gate valves, electrical and mechanical interlocks, guards, electrical switches, etc.
4.4.1 Any accidental interruption of lines or equipment in service or any irregularities observed must be reported to the owner's represen tative immediately. 4.5 Unsafe shortcuts, such as walking pipelines, sliding down pipe or stanchions and cutting corners to save a few steps, must be avoided. 4.6 Tools, materials or equipment must not be intentionally dropped or thrown from one level to another unless adequate precautions have been taken to assure that no injury to persons or damage to equipment will occur. 4.7 Personnel must not ride a load being handled by a crane. Slings, hooks, etc., must not be ridden, except where a crane basket or a bosuns' chair and safety belt are used. 4.8 Personnel must not walk, drop or jump onto a transite roof. Care should be exercised while erecting new transite roofs.
-7-
ST0028276
5.0 VEHICLES AND TRAFFIC
5.1 Personnel will comply with all safety rules and signs regarding traffic and vehicles at all times
5.2 The maximum speed limit on open roads in the plant is 25 miles per hour and 10 miles per hour within work areas, unless otherwise designated by signs.
5.3 Vehicles stopped on plant roadways for the purpose of loading or dis charging passengers must not be passed in either direction except, after com ing to a complete stop, the vehicle may be passed at no more than 10 miles per hour provided the way is clear,
5.4 Fuel tanks on motorized equipment must not be filled while the engine is running or when welding or other hot work is being done nearby. Smoking will not be allowed during fueling operations
5.5 Equipment such as welding machines, pumps, etc., shall not be transported with the engine running.
5.6 All equipment must be in safe mechanical working condition at all times. In addition to complying with state requirements as to brakes, lights, signals, horns, mufflers, etc., vehicles must be periodically inspected by a represen tative of the contractor. Necessary repairs and adjustments must be made prior to their use on owner s property
5.7 The use of winch trucks, flatbeds. stakebeds. etc., as transportation for personnel will not be permitted unless adequate safety provisions are made and the vehicle is adapted for that purpose. In any case, the number of per sonnel must not cause overcrowding.
5.8 Riding of "Cherry Pickers" or cranes is permitted only when adequate safety provisions such as seats, platforms, rails, etc., are provided for passengers.
5.9 The maximum number of people who may ride in a pickup truck is three in the cab and six seated on the floor of the bed, or on approved "built-in" seats
5.10 Personnel must be sitting down at all times when the vehicle they are riding is in motion and must not have any part of their body over the sides.
5.11 Pedestrian paths and walkways must be used whenever provided. In their absence, personnel using streets and roadways must walk facing ap proaching traffic, on left-hand side of road
5.12 The following rules must be observed in the operation of cranes, cherry pickers, winch trucks and other equipment having booms or extended loads which extend 15 feet or more in front of or to the rear of the equipment.
5.12.1 Stop at all stop signs
5.12.2 At intersections, when the equipment is to proceed straight across a thoroughfare or turn either way. the equipment must stop; the flagman must get off the equipment, clear all traffic, then flag the equip ment through the intersection or around the corner.
-8-
ST0028277
5.12.3 Before entering any thoroughfare, street, road, etc., from a work area, the flagman must clear the traffic and flag the equipment onto the road. 5.12.4 All booms or loads extending more than 15 feet must be marked or flagged with high visibility material when moving on plant roads. 5.12.5 A flagman must be provided and swinging must be controlled with a tag line when moving in a congested area or where there is per sonnel. 5.12.6 Hauled material that overhangs the sides or ends of a truck must be red flagged at the extent of the overhang. Loads must not be hauled from a single suspension cable that allows free swinging beyond the sides of the vehicle. Loads or vehicles that extend out of the normal road lanes require flagman or escorts. 5.12.7 Contractors must check vertical clearances on the route to be used prior to moving equipment or high loads. 5.13 Contractors must determine from the owner's representative when and which roads are to be used, prior to moving extremely heavy loads such as large rubber-mounted equipment and low-boy loads.
-9-
ST0028278
6.0 PROTECTIVE EQUIPMENT AND CLOTHING
6.1 The contractor and his employees shall recognize the importance and the use ol special protective equipment and clothing.
6.1.1 The contractor shall be responsible for knowing and enforcing special owner area or job rules requiring special personnel protection.
6.1.2 Contractors shall provide their employees with the proper protec tive equipment required.
6.2 Approved safety glasses shall be a minimum requirement on all jobs at all times. Safety glasses with side shields are required when grinding, chip ping or performing any job where side shields would afford protection from fly ing particles.
6.2.1 Approved safety glasses must fulfill federal requirementsfGGGG-513) for drop ball testing and safety code for polarized "Strain" pattern.
6.2.2 Employees wearing contact lens must wear chemical goggles.
6.3 Chemical goggles, approved prior to their use. are required for working in or entering certain chemical areas which are posted with signs, or while doing chipping or power tool cleaning work on pressurized lines or equipment which contains hazardous chemicals
6.3.1 All employees working in the vicinity of hazardous chemicals must know where the nearest safety shower and eye bath facilities are located.
6.3.2 When chemical type goggles are m use, the headband must be around the back of the head, not around the safety hat.
6.4 Approved safety hats are required for all contractor work. Metal hats must not be used where electrical hazards exist.
6.4.1 Approved safety hats must fulfill requirements in Federal Specification GGG-11 -142b. The maior requirement in this specifica tion says, "The specimen must withstand the drop of an 8-pound spherical weight, approximately 3.8 inches in diameter, from a distance of 5 feet, without breaking the hat. bottoming out or breaking suspen sion." Most skull caps, scalp guards, bump helmets, etc., will not meet this test. Safety hats shall not be drilled or punched for ventilation holes, or edges trimmed off hats.
6.5 All personnel shall wear air hoods, or equivalent, supplied with filtered air, when sandblasting or applying volatile or toxic material inside tanks, rooms or any other area not adequately ventilated
6.6 Safety belts or harnesses, with lifelines attached, are to be worn by employees when performing work in elevated positions where the use of scaf folds or ladders is impractical and where a slip might result in a serious fall.
6.7 Personnel must wear owner approved life jackets or otherwise be protected by handrails or lifelines when working over water wherein a drown ing hazard exists.
-10-
ST0028279
6.8 Personnel shall wear personal clothing that is safe and proper for their job. Wearing of canvas shoes, sneakers or houseshoes and working in an un dershirt, shorts or stripped to the waist, is prohibited. Safety shoes are strong ly recommended. 6.9 Fixed blade knives used as tools of the trade must be carried in sheaths while not in use.
-11-
ST0028280
7.0 FIRE PROTECTION
7.1 Accumulation of trash, oily rags, combustible materials and similar fire hazards of any nature will not be permitted.
7.2 The area around welding operations must be kept free of hoses and flam mable material of all kind.
7.2.1 There must be afire ext inguisher or water hose easily accessible for each welding, cutting, burning or other such operations, located in close proximity to the operation. It is the contractor s responsibility to ob tain the required fire extinguishers for his welding operations.
7.2.2 Special care must be taken during overhead welding operations to safeguard personnel and prevent falling sparks from starting a fire.
7.3 All tarpaulins shall be fire-retardant and identified as such by stenciling: "FR-treated (date)" with a minimum of two-inch letters in diagonal corners. In lieu of this treatment, fireproof blankets such as fiberglass or asbestos are acceptable.
7.3.1 Contractors must inspect and test all tarpaulins at least once each six months to be sure that they are still fire-retardant. Tarpaulins needing it must be retreated or removed from the plant immediately. At this time the tarpaulins must be restenciled in the same manner as in 7.3 above.
7.4 Fire plugs, extinguishers, hose racks and other emergency equipment, shall not be covered or blocked and fire equipment lanes must always be kept clear.
7.5 All heating units for offices, shops, work areas, change rooms, etc., must be in good working order and periodically inspected. Gas units must be provid ed with "flame-out" protective devices and electrical units must begrounded. All heating units must be turned off at the end of each work day.
7.6 Flammable or explosive type material such as fuel, oil, cleaning agents, etc., must be properly contained, clearly identified, separately stored and kept clear of work areas. Appropriate signs must be provided in storage areas.
7.7 All cans used for transporting or transferring gasoline or fuel must be labeled by Underwriters' Laboratories or Factory Mutual Laboratories.
7.8 Fuel storage tanks, filler hoses and the dispersing vehicle or containers must be properly grounded.
7.8.1 A quick shut-off valve is required on the dispensing end of fuel hoses.
7.8.2 Equipment fuel tanks must not be filled while the engine is run ning.
7.8.3 Smoking, welding or any spark- or flame-producing operation must be stopped in the immediate area during refueling operations.
7.9 Welding rod cabinets presenting a fire or safety hazard will not be per mitted. Cabinets of fireproof materials equipped with strip heaters are recommended. If light bulbs are used, they must be securely guarded with adequate spacing in regard to the cabinet and to stored material. Metal
-12-
ST002828 I
cabinets must be grounded in an approved manner. 7.10 Volatile materials must not be applied near an open flame. If such material is to be applied in a vessel, or other poorly ventilated, confined area, only explosion-proof lights and connections will be used. The contractor must designate such areas as "No Smoking." 7.11 Heating equipment for freeze protection of concrete must be approved by the owner s representative prior to use. 7.12 Welding or cutting torches and hoses must not be connected to cylinders when stored in any enclosure or building. When work is shut down and equipment is unattended, close all valves at the gas and oxygen cylinders, bleed lines and check five minutes later for pressure build-up. If there is no build-up, bleed hoses at the torch, remove hoses from cylinders and store. No smoking will be permitted during this shutdown procedure. 7.13 Gas and oxygen cylinders must be handled with care, properly sup ported in an upright position away from any source of heat or flame and securely tied off. All cylinders not in use must have their caps in place and stored as above.
7.13.1 Oxygen cylinders in storage and not in use must be separated from gas cylinders by a fire retardant partition or a minimum distance of 10 feet. 7.13.2 When gas and oxygen cylinders are lifted by hoisting equip ment, a basket, a cradle, or similar handling device must be used. Cylinders must not be lifted by the valve protection caps. 7.14 All "No Smoking" restrictions must be strictly observed. Smoking is not permitted in vehicles in designated "No Smoking" areas. 7.15 Compressed gases must not be used for cleaning of clothes, the body or work areas. Oxygen must not be used for pressure testing purposes. 7.16 Adequate ventilation must be provided when cleaning agents are used.
7.17 Contractors must not dump flammable or toxic materials into sanitary sewers or waste water system without prior clearance of the owner's representative.
-13-
ST0028282
8.0 MACHINERY, TOOLS AND EQUIPMENT
8.1 The safe designed capacity of any tool or piece of equipment must not be exceeded. Tools and equipment must not be modified in any manner that reduces the original safety capacity.
8.2 All contractor owned, leased or rented equipment must be in safe mechanical working condition to render safe service at all times.
8.2.1 Equipment must be inspected by contractor supervision prior to its use on a job and periodically thereafter to insure that it is in safe working order. Crane inspection must be submitted in writing to owner's representative using the owner's' Hoisting Equipment Inspec tion" form. (See Sample.) Special attention must be given to such items as cables, guards, booms, blocks, hooks, grounds, electrical cords and safety devices. Equipment must be shut down before repairs or ad justments are made
8.2.2 Defective tools and equipment must be removed from the job im mediately and if repairable, must be properly repaired before .reuse on owner s job.
8.2.3 Machinery, tools and equipment must not be operated without all guards and safety devices m place and functioning properly.
8.2.4 The contractor has the complete responsibility for a safe opera tion when using hoisting equipment to make lifts. The contractor shall verify weights of loads to be lifted. No load shall be lifted which exceeds the manufacturer s rated capacity of the crane. When one of the follow ing conditions prevail, the contractor must submit in writing, using the owner s "Check List for Critical Lifts" (see sample), an outline of the safety planning for the lift to the owner's representative prior to starting the lift.
a. The load exceeds 80 percent of rated load charts for crane.
b. The load exceeds 50 percent of rated load chart for crane, and possible failure would endanger existing facilities.
c. Two booms are required to make the lift.
d. Poles or derricks have been erected for this specific lift.
8.2.5 If burning of lugs or other such flame-producing operations may be required during crane hoisting operations, arrangements for proper safe work permits must be made before the lifting operations begin.
8.3 Equipment with exposed gears, belts, couplings, etc., must be provided with proper guards.
8.4 Electrical tools and equipment operating at more than 32 volts must be properly grounded. Certain test equipment such as oscilloscopes, vacuum tube voltmeters and signal generators, as well as certain areas where exposed d-c equipment is used, do not require grounding and proper operational procedures must be ascertained from the owner s representative.
8.5 Only 32-volt, or less electrical service is to be used in connection with drop lights when working inside metallic vessels, unless 115-volt service is essential for the operation of equipment
-14-
303*17#
HOISTING EQUIPMENT INSPECTION REPORT
(Use Hydraulic Crane Inspection Form for Hydraulic Cranes)
OWNER__________________________________________ ______________
DATK_________________ EQUIPMENT NO.
MANUFACTURER/MODEL________________________ _____________ MAXIMUM CAPACITY-----------------------------------------------------------SERIAL NO___________________________________ __ __________ DATE OF MANUFACTURE____________________________________ COUNTERWEIGHT FOR NORMAL USE_________________________ BOOM LENGTH FOR NORMAL USE COUNTERWEIGHT FOR CAPACITY LIFT_____________________ BOOM LENGTH FOR CAPACITY LIFT_______________________ CAPACITY CHART POSTED IN CAB ( ) YES ( ) NO
CONDITION
.1. Identification and high visibility markings
2 Hooks (pins-swivels) 3. Boom sheaves and blocks (straps)
4. Traveling block (pins-grease fittings)
.5. Cable drums (facing and becket)
6 Hoist lock (catch on brakes) 7. Clutches (bands-pins-cotter pins)
.8 Whip line (condition of cable, age)
9. Load line (condition of cable, age) Boom line (condition of cable, sockets, age)
11. Boom and jib pendants (condition of cable, sockets, age)
.12 Main boom (structural members - pins)
13. Jib (structural members - pin's) 14. Gancry (A-frame) - (pins-sheaves-straps)
15. Swing lock
16. Hydraulic or air system
17. Lighting system 18. Painting
19. Drive chains (tension)
.20 Tires (air pressure-damage)
.21 Steering mechanism .22 Counterweights (adequate or not)
23. Cab, platforms, handrailing, steps, glass, etc. (access) 24. Fire extinguisher
25. Boom hoist safety device 26. Power lowering - whip line
27. Power lowering - load line 28. Boom base pins
29. Housekeeping
CO
----{
CD
CD
PO
CO
ro co co
OVERALL EVALUATION OF CONDITION
( ) Good, Safe
( ) Fair, Safe
( ) Unsafe
Inspector (Owner)___
Audited by (Dow)_____ Tag No.________________
Date
-15-
ST0028284
90S* '74
CHECK LIST FOR CRITICAL LIFTS
1. ACC. #/W. 0. * . 2. JOB DESCRIPTION
3. LOCATION________________________________________ 4. DOW REPRESENTATIVE__________________________ 5. PLAMsIING DATA:
A. 1. CONTRACTOR _____________________________ 2. SUPERINTENDENT____________________ 3. SUPERVISOR RESPONSIBLE FOR LIFT
B. DESCRIPTION OF ITEM TO BE RAISED _
C. MAJOR HOISTING EQUIPMENT TO BE USED (MUST INCLUDE INSPECTION TAG NUMBER AID DATE. TAGS ARE VALID FOR FOUR MONTHS.)
1
2. _
3._
4
D. EQUIPMENT LIFT RELATIONSHIP 1. OPERATING RADIUS 2. BOOM LENGTH 3. ALLOWABLE LOAD (FROM LOAD CHART) 4. RATIO OF LIFT TO ALLOWABLE LOAD
-16-
ST0028285
CHECK LIST FOR CRITICAL LIFTS
90S.174
PAGE 2
5. CLEARANCE BETWEEN BOOM 6 LIFT________ 6. CLEARANCE TO SURROUNDING FACILITIES
E. SCHEDULE OF OPERATIONS (INCLUDE TIME FOR RIGGING G EQUIPMENT INSPECTIONS).
6. BASIS FOR CRITICAL LIFT:
A. LOAD EXCEEDS 80- OF LOAD CHART FOR CRANE OR DERRICK____________
8. LOAD EXCEEDS 50^ OF LOAD CHART, AND FAILURE WOULD ENDANGER
EXISTING FACILITIES
____________________________________________
C. TWO BOOMS ARE REQUIRED: D. POLES OR DERRICKS HAVE BEEN ERECTED FOR THIS SPECIFIC LIFT__
7. HOW WEIGHT OF CRITICAL LIFT WAS OBTAINED:
A. CERTIFIED SCALE WEIGHT
'
8. CALCULATED INDEPENDENTLY BY MOPE THAN ONE SOURCE.
1. SOURCE WEIGHT
2. SOURCEWEIGHT
C. IF LIFT IS AN EXISTING ITEM (BEING REMOVED OR DEMOLISHED), THE
WEIGHT IS TO BE RECALCULATED, TAKING INTO ACCOUNT ALL MODIFICA
TIONS INCLUDING INTERNAL AS WELL AS AN ALLOWANCE FOR SCALE,
SEDIMENT, SLUDGE, INSULATION, LIQUID, ETC.
1. SOURCE WEIGHT
2. SOURCE WEIGHT
-17-
ST0028286
CHECK LIST FOR CRITICAL LIFTS
01-l 74
PAGE 3
8. CONDITION OF HOISTING EQUIPMENT S RIGGING: A. HAS EQUIPMENT BEEN RE INSPECTED FOR THIS LIFT? B. HAS ALL EQUIPMENT & RIGGING BEEN INSPECTED AND FOUND IN ACCEPT ABLE CONDITION FOR THIS LIFT?
9. GUYS ANCHORS S GUYS: A. ADEQUACY OF FOUNDATION FOR FOOT BLOCKS B. ADEQUACY, NUMBER, AND LOCATION OF GUYS ANCHORS
C. FOOT BLOCKS ARE TO BE ANCHORED________________________________________ D. CONDITION OF ALL CABLE, INCLUDING SPLICES, CLAMPS; THIMBLES, AND
OTHER HARDWARE
10. STABILITY OF GROUND AREA: A. CHECK SOIL BEARING ALLOWABLE LOAD______________________________ B. WILL MATS BE REQUIRED?______________________________________________ C. ANY UNDERGROUND INSTALLATIONS NEEDING SPECIAL TREATMENT
11. OPERATORS: WHAT IS OPERATOR'S EXPERIENCE ON THIS EQUIPMENT AND THIS TYPE OF LIFT?
12. REMARKS:
-18-
ST0028287
CHECK LIST FOR CRITICAL LIFTS
- 1 - 4
PAGE A
NOTHING IN THIS SUBMISSION AND/OR ACCEPTANCE OF THIS CHECK LIST IS TO BE CONSIDERED AS RELIEVING THE CONTRACTORS OF ANY RESPON SIBILITY FOR A SAFE OPERATION.
by:___ TITLE:
CONTRACTOR
RESUME OF ACTUAL SCHEDULE: DATE OF LIpT_____________________ INSPECTIONS COMPLETED_________ LIFT STARTED_____________________ PERMANENT SUPPORTS COMPLETED TOTAL TIME________________________
-19-
ST0028288
8.6 When arc welding is being done in an area restricted by a safe work per mit, the grounding lead must be connected to the work within the limits as provided in the safe work permit. 8.7 Any contact provision for connections to an owner's plant services for construction use must be cleared with the owner s representative. Authorized connections must be made under the direction of the owner's personnel. The turning off and on of the supply shall be done only by authorized owner's per sonnel. 8.8 Gloves must not be worn while using grinders, drills, saws or any tools where gloves are apt to become entangled. 8.9 Loose clothing must not be worn while working around machinery. 8.10 Personnel must not crank any machinery with their feet. 8.11 Hose connectors and adaptors must be of a standard manufacture and used only for the type of service intended.
8.11.1 In order to insure positive locking at all times, connectors must be in good condition and not abused. Sandblast hose connections shall be the safety lock type which prevents accidental disengagements. 8.11.2 Air pressure on pneumatic tools must be bled down before tools are disconnected from air supply.
-20-
ST0028289
9.0 LADDERS AND SCAFFOLDS
9.1 All ladders must be of the proper length and in good condition before us ing them. All unacceptable ladders must be immediately removed from owner's property.
9.1.1 Ladders are not to be painted with anything other than clear paint or linseed oil.
9.1.2 All straight ladders must be tied off or held. Stepladders higher than ten feet must be tied off at the top or held at the bottom by another workman. Personnel must not stand on the top step of any stepladder.
9.1.3 When climbing a ladder, personnel must face the ladder and keep both hands free for climbing.
9.1.4 Set straight ladders so that the bottom is out from the vertical about one-fourth of the distance from the upper support to the bottom.
9.1.5 All ladders should be provided with nonskid adjustable feet or properly supported on a level surface
9.1.6 The area around the bottom of all ladders must be free from slippery substance and tripping hazards.
9.1.7 Ladders are not to be used as pencil or scaffold boards.
9.1.8 The top section of extension ladders are not to be used by themselves.
9.2 The use of No. 9 soft annealed wire should be minimized on scaffolds.
9.2.1 When No. 9 soft annealed wire is used, a minimum of two separate strands must be used to tie scaffold handrails, braces, etc. The ties must be crossed to form a lock and prevent slipping in any direction.
9.2.2 Do not reuse No. 9 wire for any purpose.
9.3 Makeshift scaffolds such as boxes, crates and drums must not be used.
9.4 Wood scaffolding, aluminum ladders, aluminum scaffolds and aluminum pencil boards are not permitted except in special cases as specified in operating area rules and job specifications or by prior written approval from the owner's representative
9.5 The following rules apply to all patented metal scaffolds:
9.5.1 Scaffolds must be erected with proper fixtures made for each type of scaffolding. Scaffolds and associated equipment must not be modified m any manner that reduces the manufacturer's designed performance.
9.5.2 All scaffolds and allied equipment must be kept in good repair.
9.5.3 Equipment that is damaged or deteriorated to the extent that it is unsafe shall not be used. Such equipment shall be removed from the owner's property.
9.5.4 Compensate for unevenness of ground by using adjusting screws in addition to proper blocking.
-21 -
ST0028290
9.5.5 Do not force braces to fit. Adjust evenness of scaffold until the proper fit can be made with ease.
9.5.6 Use ladders when climbing scaffold rather than the cross braces and handrails.
9.5.7 Personnel shall use ladders when climbing scaffold rather than the cross braces.
9.5.8 Horizontal diagonal bracing shall be used at bottom and in termediate levels of thirty feet to prevent racking of all scaffolds.
9.5.9 Planking overhang shall be 3-5/8" on stackup scaffolds. 1 "by 4" wood cleats shall be nailed across top of planking at each end outside end frames. 2" by 2" cleats shall be bolted underside each end of plank with 2-1/4" stove bolts.
9.5.10 The maximum span for guying or tying off all fixed towers is every 18' of elevation.
9.6 The following rules apply to rolling tower scaffolds:
9.6.1 The minimum base dimensions for towers shall be 5' by T.
9.6.2 Towers of a height greater than three times the minimum base dimension must be guyed or tied off while being erected, used or dis mantled.
9.6.3 Caster brakes must be applied when not in motion.
9.6.4 Towers must be free of men, material and equipment while being moved. Care must be exercised while moving.
9.6.5 Surface area where tower is being moved shall be free of rubble or any material that may cause the tower to tip.
9.6.6 Do not attempt to move a rolling tower without sufficient help.
9.6.7 Do not extend adjusting screws beyond the limits specified by the equipment manufacturer.
9.6.8 The minimum size for casters shall be 6". Scaffolds higher than 25' must be stabilized either with outriggers or hand lines while being moved.
9.6.9 Horizontal diagonal bracing is to be used at the bottom and at in termediate levels of 30 feet.
9.6.10 Do not use knee braces or cantilevered brackets on rolling towers.
9.7 The following rules apply to suspended scaffolds:
9.7.1 Chains or 1/4" (minimum) steel cable shall be used to support suspended scaffolds. All suspended scaffolds shall be anchored to pre vent swinging. Chains so used shall be made of not less than 1/4" links* and shall be inspected immediately prior to each use.
22-
ST002829 I
Span in Feet
6 8 10 12 14 16
TABLE I SAFE CENTER LOADS FOR SCAFFOLD
PLANK IN POUNDS
SIZE OF PLANK
2 x 10 Dressed
To
1 5-8 x 9'.-
2 x 12 Dressed
To 1-5/8 xir,
3 x 10 Dressed
To
2-5/8 x 9'.
3 x 12 Dressed
To 2-5/8 x 11'/,
256 309 667 807 192 232 500 605 153 186 400 484 128 155 333 404 110 133 286 346
116 250 303
Nominal Timber Size
2x4 4x4 2x6 2x8 2x 10 2x 12 3x8 3x 10 3 x 12
5
440 725 780 1400 2190 2800 2100 3290 4525
TABLE II SAFE CENTER LOADS ON TIMBER USEO AS
BEAMS IN POUNDS
LENGTH OF SPAN IN FEET
6
290 575 650 1150 1820 2630 1730 2750 3940
8
210 420 470 850 1350 1950 1290 2120 2920
10
330 360 660 1050 1530 990 1590 2300
12
260 290 530 860 1250 810 1300 1880
14
215 240 450 710 1050 680 1070 1570
16
190 370 600 890 560 900 1340
20
270 450 670 410 670 1000
24
190 320 510 290 490 660
TABLE III
SAFE LOADING FOR SIMPLE MATERIAL HOIST ON CANTILEVER BEAM IN POUNDS
LENGTH OF CANTILEVER (B) IN FEET
Beam Size 2 3 4 5 6 7 8
4x4 220 160 105 80 65
4x6 495 320 260 190 150 125 105
6x6 740 490 360 285 230 190 160
6x8
1325
875 650
515
420
350
300
8x6
1765
1165
865
685
560
470
400
Horizontal dimension from front bearing to rear anchor must be equal to or greater than cantilever Protection "B" in table
23-
ST0028292
*1/4" proof coil loading chain Safe Load
900 lbs.
5/16" proof coil loading chain Safe Load
1,360 lbs.
5/16" proof coil loading chain Proof-tested Safe Load
2,720 lbs.
5/16" proof coil loading chain Unlimited Safe Load
5,440 lbs.
9.7.2 The suspended support must be insulated when arc welding is to be performed from platform, thus avoiding accidental arcing and subse quent failure.
9.7.3 Block and falls shall be a minimum of two sheaves for 3/4" rope and the minimum size rope shall be 5/8". Acid resistant rope shall be used in acid or caustic areas. Tail ropes shall be placed in an open con tainer for protection while used in an acid area or above operating machinery, pumps, etc. All ropes and blocks must be inspected and tested prior to each use and taken down and stored inside at the end of each work day.
9.8 The following rules apply to all scaffolds:
9.8.1 Scaffolds and related material shall be carefully inspected at regular intervals and particularly just before using.
9.8.2 Provide sufficient sills or underpinning on all scaffolds to be erected on filled or otherwise soft ground. Scaffold boards shall not be used for this purpose.
9.8.3 All scaffolds must be plumb and reasonably level at all times.
9.8.4 Anchor running scaffolds to wall approximately every 28' of length and 18' of height. Use additional care when using pulley arms.
9.8.5 Handrailing and access ladders must be used on all scaffolds regardless of height. Scaffolds higher than 30' around columns, tanks, etc., must have access ladders constructed on the inside, unless a ladder cage is provided. Handrails must be at a height sufficient to provide maximum personnel safety.
9.8.6 Scaffolds must not be used as material hoist towers or for mount ing derricks without first determining the loads and stresses involved.
9.8.7 Erect scaffolds in such a manner that ladder is accessible and lined up from top to bottom.
9.8.8 Lumber used in the construction of platforms shall be of good quality and reasonably straight grained, it shall be free from defects such as injurious ring shakes, checks, splits, cross grams, unsound knots, knots in groups, decay and growth characteristics or any other defect which materially decreases the strength of the lumber. Planking shall not be painted all over, as this would conceal any defects. Scaffold boards shall be identified by painting each end. All scaffold boards shall be used exclusively for that purpose Nothing less than 2" by 4" material shall be used as handrails on wooden scaffolds
24-
ST 0020293
9.8.9 The normal size of planking shall be determined from Table I. These values are for planks with the wide face up. with the loads concen trated at the center. Loads given in the table are net. Allowance has been made for the weight of the planking. If select structural coast region Douglas fir, merchantable structural square and sound southern pine are used, the loads may be increased 45 percent. 9.8.10 Planks used for platforms shall be of uniform thickness, laid close together. These planks must be overlapped at the bearers. An overlap of at least 2' must be allowed with the bearing in the center of the overlap. When planks overhang a bearer more than one-tenth of the length of the span, the planks must be securely fastened to the bearer at the opposite end to prevent tipping. 9.8.11 All nails used in scaffold construction shall be driven full length. If double headed nails are used, they shall be driven to the first head only and may not be used on platforms or walkways. No nail smaller than 8d shall be used in this construction. The design must be such that no nail is subject to a direct pull. 9.8.12 Where beams are used in scaffolding, the schedule of loads shown in Table It shall be followed. Loading on cantilever type beams for tool and material hoists is shown in Table III. It should be noted that the loading at the center of bearing point is 4 times as great as the load being lifted and the bearing should be checked to ascertain if it will support the contemplated load. The inboard end of the beam has a force upward of twice the load and must be securely fastened with no nails indirect pull. 9.8.13 Platforms shall be kept clear of slippery substances and tripping hazards.
25-
10.0 DANGER WARNING AND CAUTION TAGS
16282001S
10.1 Danger Tags (Red)
10.1.1 To insure (hat operating status of equipment is not changed while it is being used or worked on. red danger tags must be attached to the controls so that personnel will know not to use them. These tags must be used to protect personnel exposed to hazards of equipment and must be respected by all personnel. The personnel responsible for the operation of equipment or their designee must clear and tag the equip ment. Any personnel whose safety could be endangered while working on this equipment must affix their tag Violation of red danger tag rules will result in disciplinary action up to and including rejection from any work on owner's property
10.1.2 No control such as a valve, switch, clutch, etc., is to be operated by anyone while a red danger tag is attached. If a control must be operated intermittently such as for testing equipment, the red danger tag must be properly removed before each operation Attachment of danger tags to equipment controls does not mean that equipment has. been cleared to work on. When work is to be done on tagged-out equipment, personnel responsible for the operation of the equipment are responsi ble for clearing the equipment and making it safe for others to work on.
10.1.3 Whenever the operation or use of any equipment may endanger anyone, a request must be made to supervision of the group which operates the equipment to clear and tag the equipment. "Clearing" means making the equipment inoperable and safe for others to work on. The authority to clear and tag equipment may be delegated by this super vision to any qualified personnel after supervision has assured themselves that the person delegated can properly clear the particular job involved.
10.1.4 After the group which operates the equipment has cleared and tagged the equipment, each worker or group of workers who may be ex posed to the hazards must tag the equipment for their protection. When red danger tags are attached to equipment by persons other than those responsible for its operation, prior approval from the person responsible shall be obtained.
10.1.5 As the individual jobs have been completed, each worker or group of workers must remove their tags immediately.
10.1.6 The group responsible for the equipment must place their tag first and remove their tags last.
10.1.7 Red danger tags may be removed only upon authorization of the
person designated on the tag.The supervisor of any person who fails to
remove a red danger tag when a job has been completed may authorize
the removal of the tag after he has determined to his complete satisfac
tion that the equipment can be operated in a safe manner. In the space
on the tag entitled "Removal Will be Ordered By
. 'it is permissible
to designate a classification such as shift foreman, electrician, or
machinist instead of a specific individual's name
10.1.8 At the discretion of the supervisor, locks may be used on valves and switches in addition to. but not replacing red danger tags.
-26-
ST0028295
10.1.9 Tags removed must be filled out and turned in to the owner's representative. 10.2 Warning Tags (Green) 10.2.1 When it is necessary to convey instructions or information prior to operation of equipment controls, green "warning" tags are to be at tached to the controls. 10.2.2 Green "Warning" tags should be removed when conditions set forth on the tag have been met. 10.3 Caution Tags (White) 10.3.1 White caution tags are affixed to mechanical or electric equip ment by the owner's representative to prevent operation of such equip ment by anyone until items on the tag have been completed. 10.3.2 The tag provides spaces for meggering, rotation, final alignment and lubrication of equipment. When appropriate action has been taken, the personnel performing the work signs and dates the tag. 10.3.3 When tagged equipment is released to the owner, a represen tative of operations and the owner's representative sign the tag which is kept by the owner's representative until job completion.
-27-
ST0028296
11.0 SAFE WORK PERMITS
11.1 Safe work permits issued by the owner to contractor personnel may be required for certain hazardous locations and conditions. These permits are designed to provide a means of checking at the job site the safety of such jobs as, but not limited to, entering closed vessels; working on electrical gear; welding, cutting on, breaking into or repairing pipelines or vessels in operation or under pressure or that have contained hazardous materials. These permits also cover work involving the use of flame or spark producing equipment in hazardous areas or near an open ditch and work on machinery.
11.2 Contractor supervision must be in close contact with the progress of work as well as communicating with the owner's representative for up-todate status of operations. Further, contractor supervision must be certain that all personnel involved are informed as to specific procedures and changes in the situation.
11.3 Safe work permits are to be initially requested through the owner's representative and issued by the owner's operating area or facility supervision involved on any job where the safe work permit is applicable. More than one safe work permit may be required on certain jobs which will be ascertained upon obtaining each safe work permit. Permits are issued on a day-to-day basis.
11.4 Personnel must give to the person issuing the safe work permit a careful and complete description of the work to be done.
11.4.1 Where a job presents a serious man hazard due to chemical, mechanical, electrical, temperature or height exposure, it is mandatory that a written safe job procedure accompany the request for the safe work permit. This procedure is to be signed by the owner's represen tative, process representative, and the contractor, who thereby agree that the procedure allows the job to be done safely
11.5 Directions and restrictions noted on safe work permits must be careful ly followed.
11.6 A safe work permit must be reissued for a job if there is evidence that conditions have changed subsequent to the issuance of the original safe work permit.
11.7 Permits issued for jobs that last longer than one day will normally be issued for that job each day. By mutual consent of the parties involved, permits for these jobs may be issued for longer or shorter periods of time.
11.8 Vessels in an existing facility to be entered must be made safe for per sonnel by such measures as disconnecting, blinding, or double block and bleed on connecting piping. If such precautions are impractical, a detailed procedure for performing the work m a safe manner must be prescribed as specified in Paragraph 11.4.1
11.9 Vessels in an existing facility to be welded on, or cut. must be positively checked inside for flammable or explosive gas and or liquids and safe work permits issued before heat is applied.
-28-
ST002G297
11.10 The contractor may request safe work permits for his own protection. Safety checks by the owner for dangerous gases or chemicals should be re quested through the owner's representative when there is any uncertainty.
11.11 All safe work permits in the area affected are automatically cancelled when an emergency signal is sounded and must be reissued after the all-clear signal.
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ST0028298
12.0 EXCAVATIONS, FLOOR OPENINGS, BARRICADES
12.1 Where a safety hazard would be created for any personnel, excavations such as ditches, trenches, or bell holes should be sufficiently sloped to prevent cave-ins or slides. If sloping is impractical, shoring must be used in cases whenever the vertical dimension exceeds four feet.
12.1.1 Personnel removing shoring after completion of work must not be in the bottom of the excavation. Shoring must be removed in such a manner to prevent cave-m on personnel.
12.2 Contractors must provide adequate barricades, covers, handrails, signals, flagmen, or other appropriate warning devices to protect personnel near any hazardous operation or excavation. Floor openings, open trenches, excavations, etc., shall be covered when handrails or barricades do not provide adequate protection to personnel.
12.2.1 Contractors must notify the owner's representative of necessary obstruction on road shoulders on the day it occurs.
12.2.2 Contractors must obtain approval from the owner s represen tative at least one day prior to cutting roads or otherwise obstructing traffic on plant roads. 12.3 Grade lines, ropes, chains, etc., must be sufficiently marked in order to be visible day or night.
12.4 No obstruction of any kind, whether permanent or temporary, is per mitted within 8'-9" horizontally from the centerline of any railroad track and within 22'-6" vertically from the top of the rail. Specific authorization from the owner's representative as well as blue flags are required prior to boring under or excavating adjacent to railroad tracks. Blue flags must be placed on railroad tracks when the entrance of a train would present a hazard to personnel or equipment.
12.5 In locations where strictly temporary loading or unloading operations are to be undertaken, portable derails must be used by personnel engaged in these operations to prevent overrunning of the cars by a tram.
12.6 Blue flags meeting ICC specifications, available through the owner's representative, must be placed on railroad tracks when the entrance of a train would present a hazard to personnel or equipment and in addition to, or in con junction with, derails during loading or unloading operations. Blue lights, available from the owner's representative, must be attached to blue flags at night.
12.6.1 Blue flags must be placed on the tracks so they will be in un obstructed view of the tram crew and they must be placed a minimum of two-car lengths (100 feet) in front of the end car they are intended to protect. Exceptions to the minimum distance may be made by the owner's representative where existing installations do not allow suf ficient space
12.6.2 Blue flags must be removed immediately when the hazard for which they were installed no longer exists.
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ST0020299
13.0 RADIATION 13.1 All state and/or federal laws governing use, storage or handling of a radiation source must be complied with. 13.2 A minimum of qualified people are required for the performance of any radiographic work. 13.3 In locations where a radiation source is used or stored, regulations re quire that it be marked with a "Radiation Material" sign. This sign is for the purpose of informing anyone in the area that such material is present, and not that a safety hazard due to radiation exists
13.3.1 Only authorized personnel may enter an area marked by "Radiation Area" sign. 13.3.2 All areas where a radiation hazard exists must be roped off and marked conspicuously by standard signs at a safe distance from the source of radiation. These signs bear the radiation symbol of magenta (or purple) on a yellow background with the words "Caution--Radiation Area." 13.3.3 "Radiation Area" signs must be removed when a radiation hazard no longer exists in the affected area 13.4 Equipment containing a source of radiation must not be handled, un crated or installed without prior clearance with the owner s representative.
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ST0028300
14.0 DEMOLITION
14.1 This section specifically covers the demolition (removal of facilities that have been abandoned). Due to the inherent hazards in this type of work, special care must be devoted to safe procedures, scope understanding and communications concerning the safe clearance of work.
14.2 It is not appropriate to make assumptions in any stage of a demolition job. Responsibilities must be delegated only to those whose profession qualifies them to make the necessary judgments and decisions that are re quired to assure the safest possible prosecution of the job. From start to finish, each person connected with a demolition job must adopt an attitude of "prepare for any possibility."
14.3 The contractor shall make certain that all lines, services and equipment have been cleaned or purged and properly cleared for safe removal. All lines (including water and steam) are to be considered hot until positive safe clearance has been obtained.
14.4 Special care shall be exercised to locate and mark old underground or otherwise hidden lines, cables and sewers using the best available informa tion and owner's assistance.
14.5 The prejob safety meeting with the contractor, as covered in Section 1 of this manual, shall devote special attention to preplanning the safety aspects of demolition jobs.
14.5.1 Steps of dismantling and loads to be handled shall be reviewed with the owner's representative prior to starting work.
14.5.2 Temporary provisions must be made where safety showers, eyewash baths and fire extinguishers are being moved in the work area.
ST0 5 3 3 120
Page 1 of 8
SERVICE CONTRACT
THIS CONTRACT, entered into this 12th day of March, 1976, by and between DOW CHEMICAL U.S.'A. , TEXAS DIVISION, an Operating Unit of THE DOW CHEMICAL COMPANY, a Delaware corporation with an office in Freeport, Texas (DOW), and U. S. CONTRACTORS, INC. (Contractor),
WITNESSETH^
ARTICLE I - DESCRIPTION OF THE WORK 1.01 Contractor agrees to furnish supervision and labor to
perform in a workmanlike manner the work assigned to it from time to time by Dow.
.1.02 All work to be performed hereunder shall be 'authorized by Dow in writing and shall not commence until authorization is acknowledged and accepted by Contractor or his designated repre sentative. Both Dow and Contractor shall submit to each other the name} of their personal representatives for the specific work so authorized.
1.03 Should Contractor at any time refuse or neglect to supply a sufficiency of properly skilled workmen or fail in any respect to prosecute the work hereunder with diligence, Dow may terminate Contractor's right to proceed with the work.
1.04 All work shall be performed in accordance with the individual departmental safety rules and the terms and conditions of Dow's Safety and Loss Prevention Manual for Contractors, a
t
Service Contract
Page 2 of 8
ST0 5 3 3 121
current copy of which has been furnished to the Contractor. Contractor shall comply with all applicable provisions of Federal, State and municipal safety laws and building codes to prevent accidents or injuries to 'persons or damage to property on or about or adjacent to the premises where the work is being performed.
1.05 All equipment, tools, safety equipment and special cloth' ing will be furnished by Dow.
1.06 This contract is an individual agreement and in no way shall affect any other contract between the parties hereto.
ARTICLE XI - COST OF THE WORK
-
2.01 Labor
(a) For performance of the work assigned to Contractor under
this agreement, Dow shall pay Contractor in accordance with the
terms set forth in Exhibit "A", which is attached hereto and made
a part hereof.
(b) Contractor's fee shall include, but is not limited to,
all salaries, wages, insurance premiums, if any, office personnel,
transportation, profit and overhead.
(1) Contractor shall be reimbursed for actual statutory
assessments for payroll taxes (FICA, FUT, SUT). Actual taxes
assessed shall be expressed as a percent of each monthly payroll
to which they apply. Each month's payroll tax percent shall be
used in invoicing each succeeding month.
ARTICLE III - INVOICING AND PAYMENT 3.01 Contractor shall submit invoices in duplicate to Dow,
attention General Accounting Department, as soon as practical at
Service Contract
Page 3 of 8
ST0533122
the end of each week, or at such time as may be requested by Dow.
Invoices are to be supported by properly authorized time reports
and such other support as Dow may require for validation of
amounts billed.
'
3.02 All such invoices shall be paid by Dow within ten (10)
Dow business days after the receipt thereof, unless any items
thereon are questioned by Dow, in which event Dow shall have the
right to withhold payment thereof until verification of both the
amount claimed and the validity of said claim. Dow's investigation
thereof shall proceed as promptly as possible, with which investi
gation Contractor shall provide complete cooperation. With respect
to invoices so questioned and later approved by Dow, payment shall
be made as promptly as possible and practical after such approval.
ARTICLE IV - LIENS 4.01 Contractor (a) shall indemnify and save harmless Dow
from any and all claims, demands, causes of action or suits of_ whatever nature arising out of the services and labor furnished by Contractor under this contract, and from all liens upon the real property upon which the work is located arising out of the services furnished by Contractor under this contract and (b) agrees to defend any suit or action brought against Dow based on any such claims, demands, or proceedings to enforce or foreclose any such liens based on any such work performed hereunder, and to pay all costs and expenses, including attorney's fees, in connection therewith or arising therefrom in a manner that will keep said property free and
Service Contract
Page 4 of 8
ST 0533 I 23
clear of all liens, claims and encumbrances arising from the perform ance of this contract by Contractor.
4.02 Contractor shall notify Dow immediately of the filing of any liens upon Dow's property upon which the work is located arising out of the services furnished by Contractor tender this contract. If required, Contractor shall furnish, (a) a good and sufficient release or waiver of lien or (b) receipts in full, together with an affidavit that the receipts cover all the services for which a lien might be filed except as covered by the releases and waivers of liens, but if any laborer or other person refuses to furnish a waiver or release or receipt in full. Contractor may furnish a bond, in an amount and with such sureties as may be approved by Dow, conditioned to indemnify Dow against any claim or lien or otherwise. In the event Contractor fails or refuses to have such lien released or furnish such bond when so required, Dow shall have the right to pay any sums necessary to obtain the release of such lien and to deduct the amount paid therefor from any sums due Contractor herexonder.
ARTICLE V - LIABILITY FOR INJURY TO PERSONS 5.01 Contractor assumes the entire responsibility and liability
and will indemnify and hold harmless Dow, Its agents, servants and employees from and against any and all losses,, expenses, demands and claims made against Dow, its agents, servants and employees, by any employee or officer of Contractor because of injury or alleged injury (including death), whether caused by Dow's negligence or otherwise, arising from any source while said employee or officer
Service Contract
Page 5 of 8
is on premises owned, operated or leased by Dow or under the control of Dow, or while said employee or officer of Contractor is perform ing under this agreement, and agrees to defend any suit or action brought against Dow based on any such alleged injury,, and to pay all costs and expenses, including attorney's fees, in connection therewith or resulting therefrom.
tizi.eesois
ARTICLE VI - INSURANCE
6.01 Insurance to be carried by Contractor shall be in accor
dance with Exhibit "B" which is attached hereto and made a part
hereof.
-
ARTICLE VII - PERMITS. LICENSES AND APPLICABLE LAWS 7.01 Contractor shall procure all other necessary, permits
and licenses, observe and abide by all applicable laws, regulations, ordinances and other rules of the State, territory or other political subdivision thereof, wherein the work is done, or any other duly constituted public authority, and further agrees tohold Dow harmless from liability or penalty which might be imposed by reason of an asserted or established violation of such laws, regulations, ordinances or other rules.
7.02 Contractor shall comply with any and all State and Federal laws regarding age, citizenship, hours, wages and conditions of employment affecting the work covered by this agreement. The wage rate to be paid by Contractor to personnel employed directly upon the site of the work shall not exceed the prevailing construction industry wage rate in the work area.
Service Contract
Page 6 of 8
S T 0 5 3 3 125
7.03 Unless this contract is within one of the exemptions provided for in Executive Order 11246, effective September 24, 1965, as amended by Executive Order 11374 signed October 13, 1967, Contractor shall comply with paragraphs (1) through (7) of Section 202 of Executive Order 11246 (as amended) which are incorporated herein by reference.
ARTICLE VIII - TITLE TO THE WORK 8.01 The title to all work completed and in the course of
construction and of all materials which are delivered and stored at the site and which will necessarily be incorporated in the work, as between Dow and Contractor shall be in Dow. All drawings, designs and specifications prepared for the work, whether furnished by Dow or Contractor shall become the property of Dow,' and upon completion of the work, or termination of this agreement, be delivered to Dow.
ARTICEL IX - INDEPENDENT CONTRACTOR 9.01 Contractor shall be an independent contractor under
this agreement and shall assume all of the rights, obligations and liabilities applicable to it as such independent contractor hereunder and any provisions in this contract which may appear to give Dow the right to direct Contractor as to the details of doing the work herein convered or to exercise a measure of control over the work shall be deemed to mean that Contractor shall follow the desires of Dow in the results of the work only.
Service Contract
. Page 7 of 8
ARTICLE X - NOTICES 10.01 Any notice or order provided for in this agreement
shall be considered as having been given to Dow if delivered personally to Dow's representative at the site of the work, or if mailed by registered mail, postage prepaid to:
Dow Chemical U.S.A. Texas Division Freeport, Texas 77541 Attention: Purchasing Department 10.02 Any notice or order provided for in this contract shall be considered as having been given to Contractor if delivered per sonally to its representative at the site of the work, or if mailed by registered mail, postage prepaid, to it at the following address: U. S. Contractors, Inc. P. 0. Box 338 Lake Jackson, Texas 77566
ARTICLE XI - PUBLICITY 11.01 Any information relative to the services performed
under this contract shall not be released or used by Contractor for publication, advertising or any other purpose without the prior written approval of Dow.
ARTICLE XII - TERM 12.01 This contract shall cancel and supersede that certain
contract dated October 20, 1975, and shall continue after the effective date hereof until terminated by either party giving to
ST0533I26
r
Service Contract
Page 8 of 8
the other party thirty (30) days' prior written notice. Contractor shall complete any and all work assigned to it by Dow prior to notice of termination, all in accordance with the terms and condi tions of this agreement.
EXECUTED as of the day and year first above written.
DOW CHEMICAL U.S.A. TEXAS DIVISION, an operating unit of THE DOW CHEMICAL COMPANY
U. S. CONTRACTORS, INC.
BV Title
/
BY _ Title
Purchasing Department
S T 0 5 3 3 127
DOW CHEMICAL U.S.A.
50983
TEXAS DIVISION FREEPORT, TEXAS 77541
ENVIRONMENTAL HEALTH REPORT
AIRBORNE ASBESTOS SURVEY CHLORINE VI, A-5024
file no.
A50-865
May 13, 1976
DATE
author _,H. N. Edwards L. R. Joe
DATE.
Summary Only one of the 85 samples analyzed for airborne asbestos was above the newly proposed level of 0.5 fibers per cubic centimeters. It is therefore concluded that workmen are not being overexposed to asbestos within the Chlorine VI area.
It is recommended that each workman be made aware of the results found, the hazards of overexposure and the necessity for keeping these levels below the prescribed limits. This informing should be documented.
m --H CD CD
CT>
CD
Distribution J. D. Dean A5024 S. F. Edquist B2401 R. E. Flake B101 W. H. Fletcher B101
L. R. Joe A5024 J. D. Laman B1226 O/F. Schumm B101
i^ile
(2) R. R. Langner 1803 Bldg.-Midland
Marlene Swank 1803 Bldg.-Midland * F. D. Axe - Pittsburg
* C. H. Van Metre - OCD
* C. E. Halphen - Plaquemine
* R. D. Olson 607 Bldg.-Midlam
* C. L. Sercu - Ohio
AN OPERATING UNIT OF THE OOW CHEMICAL COMPANY
File No. A50-865
-2-
May 13, 1976
STOOI 4620
INTRODUCTION
The Occupational Safety and Health Act (OSHA) requires that occupational exposures to airborne asbestos be controlled so that no worker is exposed to more than 5.0 asbestos fibers per cubic centimeter of air based on a count of fibers greater than 5 micrometers in length. These are determined by a timeweighted average (TWA) exposure for an eight hour work day, and no peak concentrations of asbestos more than 10.0 fibers per cubic centimeter as determined by a minimum sampling time of 15 minutes.
In July, 1976, the limit will be lowered to 2.0 fibers per cubic centimeter.
It is now proposed to lower the limit to 0.5 fibers per cubic centimeter with a peak of 5.0 fibers.
This survey was conducted at Chlorine VI to evaluate the worker exposures by personnel monitoring. The tests were taken from 12-8-75 to 4-15-76.
METHODOLOGY
Airborne samples were collected using a Bendix Permissible * air sampling pump (Bendix Corp., Baltimore, Md.). The fibers were collected by pulling air through a Millipore filter (AAWG 03700) mounted in a Millipore disposable cassette. Flow rates for the pumps were calibrated at 1400 cubic centimeters per minute and sampling times were four hours or greater (Table I). All samples were collected by L. R. Joe of Chlorine VI.
Samples were analyzed by Lee Martin of Central Laboratory using the following technique:
Four marked squares are cut from a filter about half-way from the edge to the center. This section is then placed on a. drop of clearing solution1 and placed on a microscope slide. The sample is covered with a cover slip and allowed to clear(about 15 minutes). The sample count is made on a Reichert Zetopan Optical microscope using Nomaraki interference contrast at 500 magnification. Counts are made for particles greater than 5.0 microns, and reported as fibers per filter square.
RESULTS
Results of the airborne sample analyses are shown in Table I. All levels are below the new proposed standards except one.
1 Clearing solution: 0.1 g/ml of clean Millipore filter paper in 1:1 diethyloxalate: dimethylphthalate.
File No. A50-865
-3-
May 13, 1976
CONCLUSIONS
Workmen are not being overexposed to asbestos within the Chlorine VI area.
RECOMMENDATIONS
It is recommended that each workman be made aware of the results found, the hazards of overexposure, and the necessity for keeping these levels below the prescribed limits. This in forming should be documented.
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50983
TEXAS DIVISION FREEPORT, TEXAS 775A1
ENVIRONMENTAL HEALTH REPORT
AIRBORNE ASBESTOS PERSONNEL MONITORING CHLORINE 6 BUILDING A-5024
file no A50-1304
mu: October 17. 1977
author H. N. Mwarris
T'. J. Loftus
CHECKED MlLl faALu^a. /977
DATE
Summary
None of the 42 samples analyzed for airborne asbestos was above the required level of 2.0 fibers/cc. It is therefore concluded that employees are not being overexposed to asbestos within the Chlorine 6 area.
It is recommended that each employee be made aware of the results found, the hazards of overexposure and the necessity for keeping these levels below the prescribed limit. This informing should be documented.
ST0607026
bbs
Distribution D. Dean A-5024
F. Edquist A-1201 E. Flake B-101 W. H. Fletcher B-101 T. J. Loftus A-5024 0. F. Schumm B-101 File
(2) R. R. Langner 1803 Midland Marlene Swank 1803 Midland Donna J. Roberts - 2020 Midland * F. D. Axe - Pittsburg * C. E. Halphen - Plaquemine * Paul Greenfield-Grandville, Ohio * R. D. Olson 433 Midland * C. H. VanMetre - OCD
AN OPERATING UNIT OF THE DOW CHEMICAL COMPANY
File A50-1304
-2-
October 17, 1977
INTRODUCTION
The Occupational Safety and Health Act (OSHA) requires that occupational exposures to airborne asbestos be controlled so that no worker is exposed to more than 2.0 asbestos fibers per cubic centimeter of air based on a count of fibers greater than 5 micrometers in length. These are determined by a timeweighted average (TWA) exposure for an eight hour work day, and no peak concentrations of asbestos more than 10.0 fibers per cubic centimeter as determined by a minimum sampling time of 15 minutes.
It is now proposed to lower the limit to 0.5 fibers per cubic centimeter with a peak of 5.0 fibers.
This survey was conducted at Chlorine 6 to evaluate the worker exposures by personnel monitoring. The tests were taken from 4-27-77 to 9-1-77.
METHODOLOGY
Airborne samples were collected using a Bendix Permissible air sampling pump (Bendix Corp., Baltimore, Md.). The fibers were collected by pulling air through a Millipore filger (AAWG03700) mounted in a Millipore disposable cassette. Flow rates for the pumps were calibrated at 1400 cubic centimeters per minute and sampling times were four hours or greater (Table I). All samples were collected by T. J. Loftus of Chlorine 6.
Samples were analyzed by Lee Martin of Central Laboratory using the following technique:
Four marked squares are cut from a filter about half-way from the edge to the center. This section is then placed on a drop of clearing solution1 and placed on a microscope slide. The sample is covered with a cover slip and allowed to clear(about 15 minutes). The sample count is made on a Reichert Zetopan Optical microscope using Nomarski interference contrast at 500 magnification. Counts are made for particles greater than 5.0 microns, and reported as fibers per filter square.
RESULTS
Results of the airborne sample analyses are shown in Table I. All levels are below the new proposed standards.
CONCLUSIONS6
Workmen are not being overexposed to asbestos within the Chlorine 6 area.
^ Clearing solution: 0.1 g/ml of clean Millipore filter paper in 1:1 diethyloxalate: dimetnylphthalate.
ST0607027
File A50-1304
-3-
October 17, 1977
RECOMMENDATIONS
It is recommended that each workman be made aware of the results found, the hazards of overexposure, and the necessity for keeping these levels below the prescribed limits. This informing should be documented.
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ST0025437
Page 1 of 13
SERVICE CONTRACT
THIS CONTRACT, entered into this 23rd day of October 19 78 , by and between DOW CHEMICAL U.S.A., .TEXAS DIVISION, an Operating Unit of THE DOW CHEMICAL COMPANY, a Delaware corporation with an office in Freeport, Texas (DOW), and U. S. CONTRACTORS, INC.
(Contractor),
lill^ESSETHj.
ARTICLE I - DESCRIPTION OF THE WORK 1.01 Contractor agrees to furnish supervision, labor, and
when requested, contractor owned equipment to perform ir. a work-., manlike manner the work assigned to it from time to time by Dow. ~ Contractor shall comply x*ith any and all designs, working drawings, and specifications furnished by Dow for such work.
1.02 All work to be performed hereunder shall be authorized by Dow in writing and shall not commence until authorization is acknowledged and accepted by Contractor or his designated repre sentative. Both Dow and Contractor shall submit to each other the name of their designated representatives for the specific work so authorized. The Contractor shall designate Plant A and Plant B representatives. Such Contractor representatives shall, have the auchori-zy for and exercise all direction of and control over all individual employees and agents of Contractor performing the work under this contract.
Service Contract
Page Z ot 13
ST0025438
1.03 Speed of performance being a consideration of this agreement, Contractor shall maintain such speed of performance as shall be consistent with good work in order to maintain com pletion dates. Should the Contractor fail or refuse in any respect to prosecute the work hereunder with? diligence, including but not limited to a refusal or inability to provide sufficient skilled personnel or materials, Dow may terminate Contractor's right to proceed with the work and may enter upon the premises for the purpose of completing the same and take possession of all materials and appliances thereon and finish their work by any method Dow may deem advisable.
1.04 All work shall be performed in accordance with the individual departmental safety rules and the terms and conditions of Dow's Safety and Loss Prevention Manual for Contractors, a current copy of which has been furnished to the Contractor. Con tractor shall comply with all applicable provisions of Federal, State and municipal safety laws and building codes to prevent accidents or injuries to persons or damage to property on or about or adjacent to the premises where the work is being performed.
1.C5 Contractor shall require each of its employees to comply with the above safety rules and terms and conditions of Dow's Safety and Loss Prevention Manual for Contractors and failure of any Contractor employee to fully comply with same shall constitute sufficient cause for Dow to exclude that Contractor employee or Contractor from the Dow plant site. In the event of a breach of
ST0025439
Service Contract
such rules, terras or conditions, at Dow's request. Contractor will immediately withdraw such employee from Dow premises.
1.06 The Contractor will furnish Dow approved hard hats, chemical goggles, side shield safety glasses, and required respirators. Except as otherwise provided for in this contract, all material, tools and other safety equipment will be furnished by Dow.
ARTICLE II - COST OF THE T-70RK 2.01 Labor (a) For performance of the work assigned to Contractor under
this agreement, Dow shall pay Contractor in accordance with the terms set forth in Exhibit "A" which is attached hereto and made a part hereof.
(b) Contractor's base rates per hour shall include, but are not limited to, hourly wage rates, salaries, insurance premiums, if any, office personnel, transportation-, overhead and profit. In addition to the base rate per hour as noted in Exhibit "A", the Contractor shall specify "adders" on a cost-par-hour basis in accordance with Section 5 of Exhibit "A". All other expenses will be a part of Contractor's base rate.
(c) Contractor shall be reimbursed for actual statutory assessments for payroll taxes (FICA, PUT, SUT). Actual taxes assessed shall be expressed as a percent of each monthly payroll
Transportation is defined as movement of people and equipment to the job site at starting and quitting times. Any additional movement of people, tools, materials, and equipment at the job site other than starting and quitting time will be reimbursed by Dow.
Service Contract
Page 4 of 13
ST0025440
to which they apply. Each month*s payroll tax percent shall be used in invoicing each succeeding month.
(d) Contractor shall submit as Exhibit "C" to this contract, a description of his minimum qualifications for each classifica tion he desires to furnish.
2.02 Overtime Dow, if it deems necessary, may require Contractor to work overtime. If the work has not been delayed by the fault or negligence of Contractor, as determined by Dow, Dow will pay Con tractor the overtime rate in accordance with Exhibit "A". 2.03 Equipment Contractor shall submit a list of Contractor owned equipment available for rent showing the rental rates (hour, day, week, month) of each piece of equipment. Dow will pay Contractor the lowest applicable rate (hour, day, week, month) available for the tire the particular piece of equipment is rented. It is intended that there be no third party rentals in this contract. 2.04 Material The intent of this contract is that Dow furnish all material. There may be extenuating circumstances when a Contractor may be requested to furnish material. When so requested, Dow shall reimburse Contractor the actual cost of material less any discounts Contractor may receive or be entitled to receive plus a fee of five percent (5/1) . Contractor shall take advantage of and pass on to Dow all terms of discount for prompt payment of bills.
Service Contract
Page 5 of 13
ST002544I
ARTICLE III - INVOICING AND PAYMENT 3.01 Contractor shall submit invoices in duplicate to Dow,
attention General Accounting Department, as soon as practical at the end of each week, or at such time as may be requested by 'Dow. Invoices are to be supported by properly authorized time reports and such other support as Dow may require for validation of amounts billed.
3.02 All such invoices shall be paid by Dow within ten (10) Dow business days after the receipt thereof, unless any items thereon are questioned by Dow, in which event Dow shall have the right to withhold payment thereof until verification of both the amount claimed and the validity of said claim. Dow's investiga tion thereof shall proceed as promptly as possible, with which- investigation Contractor shall provide complete cooperation. With respect to invoices so questioned and later approved by Dow, payment shall be made as promptly as possible and practical after such approval.
ARTICLE IV - LIENS 4.Cl Contractor (a) shall indemnify and save harmless Dow
from any and all claims, demands, causes of action or suits of whatever nature arising out of the services and labor furnished by Contractor under this contract, and from all liens upon the real property upon which the work is located arising out of the services furnished by Contractor under this contract and (b) agrees to defend any suit or action brought against Dow based on any such
Service Contract
Page 6 of 13
ST0025442
claims, demands, or proceedings to enforce or foreclose any such liens based on any such work performed hereunder, and to pay all costs and expenses, including attorney's fees, in connection therewith or arising therefrom in a manner that will keep said property free and clear of all liens, claims and encumbrances arising from the. performance of this contract by Contractor.
4.02 Contractor shall notify Dow immediately of the filing of any liens upon Dow's property upon which the work is located arising out of the services furnished by Contractor under this contract. If required. Contractor shall furnish (a) a good and sufficient release or waiver of lien or (b) receipts in full, together with an affidavit that the receipts cover all the services for which a lien might be filed except as covered by the releases and waivers of liens, but if any laborer or other person refuses to furnish a waiver or release or receipt in full. Contractor may furnish a bond, in an amount and with such sureties as may be approved by Dow, conditioned to indemnify Dow against any claim or lien or otherwise. In the event Contractor fails or refuses to have such lien released or furnish such bond when so required, Dow shall have the right to pay any sums necessary to obtain the release of such lien and to deduct the amount paid therefor from any sums due Contractor hereunder.
ARTICLE V - CUARANTY
Contractor further guarantees all the work to be performed under this contract against: defects in Contractor-furnished
Service Contract
Page 7 of 13
e'i'iszoois
material and workmanship up to one (1) year from the date of final acceptance of the completed work by Dow. Contractor shall, within, a reasonable time after receipt of notice, repair or replace any defect in materials or workmanship which may develop during said .one-year period, at its own expense and without cost to Dow. Dow may., at its option, repair said defect itself at Contractor's expense.
ARTICLE VI - ACCEPTANCE 6.01 The making of progress payments by Dow shall not be
construed as acceptance of the work dona up to the time of such payments, except as to such matters as are open and obvious. Dow, however, shall exercise reasonable diligence in discovering and reporting to Contractor, as the work'progresses, all labor and material which is not in accordance with drawings and speci fications so as to avoid unnecessary trouble and cost to Contractor in making good defective work.
6.02 Contractor's acceptance of final payment of any individ ual project shall be held to be a waiver of all claims against Dow or. that individual project. No partial use or occupanc}* of the work by Dow, nor any payment to the Contractor, other than final payment, shall constitute an acceptance of the work.
ARTICLE VII - LIABILITY FOR INJURY TO PERSONS 7.01 Contractor assumes the entire responsibility and liabil
ity and will indemnify and hold harmless Dow, its agents, servants
Service Contract
Page 8 of 13
W iSZO O lS
and employees, from and against any and all losses, expenses, demands and claims made against Dow, its agents, servants and employees, by any employee or officer of Contractor because of injury cr alleged injury (including death), whether caused by Dow's negligence or otherwise, arising from "any source while said employee or officer is on premises owned, operated or leased by Dow or under the control of Dow, or while said employee or officer of Contractor is performing under this agreement, and agrees to defend any suit or action brought against Dow based on any such alleged injury, and to pay all costs and expenses, including attorney's fees, in connection therewith or resulting therefrom
ARTICLE VIII - INSURANCE
....
Insurance to be carried by Contractor shall be in accordance
with Exhibit "B" which is attached hereto and made a part hereof.
ARTICLE IE - PERMITS. LICENSES AMD APPLICABLE LAWS 9.01 Contractor shall procure ail other necessary permits
and licenses, observe and abide by all applicable laws, regula tions, ordinances and other rules of the State, territory or other political subdivision thereof, wherein the work is dona, or any other duly constituted public authority and further agrees to hold Dow harmless from liability or penalty which might be imposed by reason of an asserted or established violation of such laws, regulations, ordinances or ocher rules.
Service Contract
Page 9 of 13
ST0025M.5
9.02 Contractor shall comply with any and all State and Federal laws regarding age, citizenship, hours, wages and con ditions of employment affecting the work covered by this agreement.
9.03 Unless otherwise exempted, Contractor shall comply iwich the applicable requirements of Executive Order 11246, as amended, the Vietnam Era Veterans Readjustment Assistance Act of 1974 and the rehabilitation Act of 1973.
ARTICLE X - TITLE TO THE WORK The title to all work completed and in the course of con
struction and of all materials which are delivered and stored at the site and which will necessarily be incorporated in the work, as between Dow and Contractor shall be in Dow. All draw ings, designs and specifications prepared for the work, whether furnished by Dow or Contractor shall become the property of Dow, and upon completion of the work, or termination of this agreement, be delivered to Dow.
ARTICLE XI - IDDEPEnDEI-iT CONTRACTOR 11.01 Contractor shall be an independent contractor under
this agreement and shall assume all of the rights, obligations and liabilities applicable to it as such independent contractor hereunder and any provisions in this contract which may appear to give Dow the right to direct Contractor as to the details of doing the work herein covered or to exercise a measure of control over the work shall be deemed to mean that Contractor shall follow the desires of Dow in the results of the work only.
Service Contract
Page 10 of 13
9 tI ,lS 2 0 0 iS
11.02 Contractor shall make all appropriate withholdings from the wages of its employees assigned to the work and shall, upon request, provide to Dow proof that such withholdings have been properly deposited with the appropriate Federal, State of local authority.
11.03 Contractor recognizes that its employees and agents, while employed on the premises of the Dow Chemical Company, might be working in areas where various chemicals and chemical vapors exist. In the interest of safety, Contractor- agrees that the Dew Chemical Company may, from time to time, request that the Contractor's employees submit to physical examinations to be conducted by medical personnel employed by the Dow Chemical Company. The expenses of such examinations will be paid by the Dow Chemical Company.
ARTICLE XII - NOTICES 12.01 Any notice or order provided for in this agreement
shall be considered as having been given to Dow if delivered personally to Dow's representative at the site of the work, or if mailed by registered mail, postage prepaid to:
Dow Chemical U.S.A. Texas Division Freeport, Texas 77541 Attention: Purchasing Department
Service Contract
Page 11 of 13
i'n s z o o is
12.02 Any notice or order provided for in this contract shall be considered as having been given to Contractor if delivered personally to its representative at the site of the work, or if nailed by registered mail, postage prepaid, to itat the following address:
U. S, CONTRACTORS. INC, P. 0. DRAWER 447_______________ CLUTE, TEXAS 77531_________
ARTICLE XIII - PUBLICITY Any information relative to the services performed under
this contract shall not be released or used by Contractor for publication, advertising or any other purpose without the prior written approval of Dow. This includes .the use of Citizen Sand Radios or other public communications within the Plants to disseminata information on any aspect of Dow's business or its Plants. Contractor further agrees that it will so inform its agents, servants and employee's of this restriction.
ARTICLE XI? - SECRECY AGREEMENT 14.01 In order to enable Contractor to consider or perform
the work, it has been or may be necessary for Dow to disclose to Contractor information concerning Dow's business plants, commercial practices and industrial technology including processes, drawings, flowsheets, equipment, composition, auxiliaries, associated facilities and the like or provide items such as
Service C0ccr2.cC
Page 1Z oc jlj
8<1 * 1 5 2 0 0 1 5
equipment, pares, samples, composicions and the like. Contractor'
agrees to maintain all such information received as confidential
information, and agrees that it will not disclose any of such
information to third parties or otherwise use the same without
the written permission of an officer of Dow. Contractor's
.
agreement hereunder shall remain in effect only so long and to
the extent that such information or item does not correspond
to that furnished or made known to Contractor by third parties
as a matter of right and without restriction on disclosure,
which Contractor can shew was not acquired directly or indirectly
from Dow or which becomes part of the public domain, through no
fault of the Contractor, but only to the extent known in the
public domain.
1A.C2 Contractor also agrees that if it is found necessary
to contac c third parties in order to fulfill any part of the
work, Con tractor shall so advise Dow in order that Dow's repre
sentativs may be present during ar.y such contact sc that the
need for additional agreements of confidentiality can be construed.
14. 02 Contractor further agrees that it will so inform its
agents, s ervants and employees having access to Dow information
of the cc r.fidantial nature of such information and, if requested
by Dow, will obtain from them and forward to Dow a secrecy agree--
on c heir pact in a form provided by Dow.
ST0025M9
Service Contract
Page 13 of 13
ARTICLE XV - NON-ASSIGNABILITY
This agreement shall be binding upon the heirs, successors and assigns of the parties hereto, however, Contractor shall not transfer or assign any of his rights or obligations here under or subcontract any work to be performed by him hereunder without first having obtained the written consent of Dow's Purchasing Department.
ARTICLE XVI - TERM This contract cancels and supersedes those certain contracts
dated March 12, 1976 and March 15, 1976, and shall continue for one calendar year after the effective date hereof or until ter minated by either party giving to the other party thirty (30) days prior written notice. Contractor shall complete `any and all work assigned to it by Dow prior to notice of termination, all in accordance with the terms and conditions of this agreement
EXECUTED as of the day and year first above writt DOW CHEMICAL U.S.A. TEXAS DIVISION, an operating unit of THE DOW CHEMICAL COMPANY"
U. S. CONTRACTORS, INC.
Title
Purchasing Department
-*SS>HOLD HARM LESS* RESPONSIBILITY-INSURANCE AGREEMENT
July..3.................. 19...7Z
NOTE TO CONTRACTOR: This is submitted in duplicate. If the terms and conditions herein meet with vnur approval, please sign and return'one copy for our files. This agreement applies to all work performed by you in Dow's plant under any contract or purchase order until cancelled hy either party by fifteen < 15) days' prior written notice.
I. Hold Harmless: Contractor assumes the entire responsibility and liability and will indemnify and hold
harmless DOW, its agents, servants and employees from and against any and all losses, expenses, demands and claims made against DOW. its agents, servants and employees. t>y any employee or officer of Contractor or its subcontractor, because of injury, or alleged injury (including death), whether caused by DOW's negligence or otherwise, arising from any source while said employee or officer is on premises owned, operated or leased hy DOW or under the control .of DOW. or while said employee or officer of Contractor or its -' ' subcontractor is performing under this agreement and agrees to defend any suit or action brought against DOW based on any such alleged injury, and to pay all costs and expenses. ^ including altomey's Ices, in connection therewith or resulting therefrom.
11 Responsibilities:
1. Contractor shall be an independent contractor under this agreement and -.hall assume ah of the riglus. obligations and liabilities applicable to it as such independent contractor hereunder and any provisions in this contra-'t which may appear to give DOW the right o direct Contractor as to the details of doing the work herein covered or to exercise a meuifr.1 of control over the work shall be deemed to mean that Contractor.shell follow the desires of DOW in the results of the work only.
2. lie.less any agreement covered hereunder is within one of the exemptions provided lor in Executive Order 1124b. effective September 24. 1905, as amended by Exeeut- e Order 113VS >ined October 13. 1Contractor shall comply with paragraphs (1) through (/ of Section 202 of Executive Order I I 24( (as amended) which sjre incorporated by reference rerein.
OeBEESOiS
A %w
M! ti*
!. /';.*
'.t-.u'J Civcw. DOW. ,ii its c* jvnsc. >iul! provide insurance pro-
i.'.'mj! -It.- -
damage or i,:<s arising :rom fire, explosion, windstorm. riot or civ'
'rmi.ior le-vage. .-.moke. aircraft. land vehicle, and ligiuning. said insurance to
the ir . V' til*: Cootructrv in the work and at! supplies, materials, equipment,
."tuniner.-. -.hi .uvraratus entering in.o or used in the construction of the work, including
expandable i.etns of Contractor's property which arc used in, or ar: incident to. the con
struction of the work but; do not become a part thereof (such as. temporary sheds, scaffold-
inn. forms and the like), and which are not otherwise insured, ail while in. on or about the
work, or at. or within one hundred (100) feet of the site thereof, but excluding all non
expendable j.'tns of property, whether owned by the Contractor or for which Contractor
is liable. whi:n are used in or are incident to the construction of the work but do not
become a part thereof.
2. Contractor's /mwa/tce-During the term of this agreement and untii final accept ance by DOW of all work to be performed hereunder. Contractor shall carry the following minimum insurance:
(a) Full coverage and compliance under the Workmen's Compensation laws of
the Slate of Texas.
(b) General Public Liability insurance in an amount not less than S300.000.00
covering accidents including death to any one person and in an amount not
less than S500.000.00 for ar.y one accident including death involving two or
more oersons. and in -n amount not less than SI 00.000.00 covering damage
to the property of DOW and of third parties.
to) Upon each and every unit of automotive equipment operated or used by
Contractor in the performance of this contract, as follows:
I*.. 11) Automotive Puhiic Liability insurance in an amount not less than
SI00,000.00 covering accidents, including death, to one person in any
'J one accident, and not less than S500.000.00 covering accidents, includ
o ing death, to mar.* than one person in Jtv- one accident, and Automotive o Property Damage insurance in an imonut not less than SI00,000.00
Ce `!icar,!.> nf Insurance - All such insurance shall be carried in compani-.
approved ;*> DOW. and Contractor, shall furnish DOW a certificate or certificates properl*,
executed by the insurance carrier, showing all sucli insurance to be in force and said earthi-
catc or certificates shall include the following statement: 'The General Liability insurance
certified hereunder includes Contractors Assumed Liability coverage for liability assumed
by the Insured under all written contracts between The Dow Chemical Company and the
iiiM.iod." Tit.* w-.T'.ilicate or certificates shall permit the cancellation or alteration of such
1'f.lii.ies only .,:tcr ten (10) days' written notiee to DOW. which such certificate or certifi
cate* shall he furnished DOW prior to the commencement of any operations under this
agr.vment. Nothing contained in this Paragraph III should be construed as limiting the
liability assumed by Contractor under Paragraph 1.
op*r
ACCEPTFL
.....U. S. Contractors.Inc. h" MitucloO
DOW CHEMICAL COMPANY M'
Texas Division
Frceportyj^'^f h
By fAurhiip/c-J A<cru)
/? H7Z.
July 3, 1972
(DjU-I
ST0221386
S T 0 2 2 I387
CARPENTER'S HANDBOOK
r
Copyright 1978 The Dow Chemical Company Distributed by
The Trades and Operator Training Department
ST022I 388
CARPENTER'S HANDBOOK COMMITTEE
R,, Behmlander, Trades and Operator Training E. Bosco, Capital Construction Projects B. Horner, Agricultural Chemical Production R. Johnson, Trades and Operator Training E. Kintner, Research and Development M. Miller, Inorganic Chemical Production Safety D. Mitchell, Inorganic Chemical Production Oo Nelson, Plastics and Designed Polymers J. Nielson, Division Engineering M* Strom, Skilled Trades Group J. Warren, Skilled Trades Group G. Wejrowski, Construction Department
Chairman H. Wheeler, Trades and Operator Training
II
68E I Z20J.S
INTRODUCTION
The objective of this handbook is to provide carpenters with a single, basic source of information pertinent to their work. A number of Dow Engineering Standards have been inserted throughout the text where they apply to the subject under discussion? the carpenter may obtain information about sources referred to in those standards from his or her supervisor. An index of Dow Safety Standards has been included in Section A; should a carpenter wish to review those standards, a copy may be obtained from his or her supervisor.
Ill
S T 0 2 2 I390
ACKNOWLEDGEMENTS
Newberry, W. G., HANDBOOK FOR RIGGERS, W. G. Newberry, 1977, Calgary, Alberta, Canada.
PLACING REINFORCING BARS, Concrete Reinforcing Steel Institute, 1974, 1976, Chicago, Illinois.
Reband, P,,, RELATED MATHEMATICS FOR CARPENTERS, American Technical Society, 1974, Chicago, Illinois.
Smith, R.C., PRINCIPLES AND PRACTICES OF LIGHT CONSTRUCTION, Prentice-Hall, Inc., 1976, Englewood Cliffs, New Jersey.
STANDARD NOMENCLATURE FOR STRUCTURAL STEEL SHAPES, American Iron and Steel Institute, 1970, New York, New York.
USING GYPSUM BOARD FOR WALLS AND CEILINGS, Gypsum Association, 1977, Evanston, Illinois. <>
NON-SHRINK GROUT AND MORTAR, SECTION III, GENERAL CATALOG, Master Builders Division, Martin Marietta Corporation, 1969, Cleveland, Ohio.
GYPSUM CONSTRUCTION HANDBOOK, United States Gypsum, 1978, Chicago, Illinois.
Sundberg, Elmer W., BUILDING TRADES BLUEPRINT READING, PART TWO, American Technical Society, 1975, Chicago, Illinois.
ACI 318-77 SP-4 FORMWORK FOR CONCRETE and ACI 304-73, American Concrete Institute, T578T Detroit, Michigan.
Jensen, C.H., ENGINEERING DRAWING AND DESIGN, McGraw-Hill Book Company of Canada, 1968, Scarborough, Ontario, Canada.
MACHINE DESIGN, Ponton Publishing/2PC, Inc., 1965, Cleveland, Ohio.
Ronald P. Smith, PRINCIPLES AND PRACTICES OF HEAVY CONSTRUCTION, 1967, Prentice-Hail, Inc., Englewood Cliffs, New Jersey.
Coggin, Armstrong, Giles, BULLETIN 2, HELPS ON SHARPENING HAND WOODWORKING TOOLS, 1938, North Carolina State College of Agriculture and Engineering of the University of North Carolina, Raleigh, North Carolina..
TV
INDEX
SECTION A - SAFETY Personal Protection Equipment Working in Elevated Positions General Safety Standard Index Erected Elevated Work Platforms Gas Torches Welding Do*s and Don'ts Working with Transite Hand Tool Sharpening
SECTION B - CONCRETE CONSTRUCTION
Concrete, General Forms for Concrete Reinforced Concrete Slabs on Ground Anchor Bolts Single and Double Pole Pipe Stub and
Foundation Details Grouting Foundations Latex Modified Concrete
SECTION C ~ CONSTRUCTION
Doors Floors Roofs Stairs and Railings Exterior Walls Interior Partitions Lumber Grades and Species Pole Buildings Lumber and Timber construction Piling
1/
Page 2 4 7 3 9
11 17 19 20 22
30 43 56 69 70
75 79 95 96
100 126 155 187 212 223 244 2^7 249 265
ST022I 39 I
SECTION D - FASTENER METHODS Nails and Spikes Screws, Washers, Bolts, Other Fasteners Portable Power Tool Drivepins
SECTION E - RIGGING Good and Bad Practices Weights of Materials and Rules of Thumb Knots Hand Signals
SECTION F - STRUCTURAL STEEL
General Safety Rules Check List for Steel Erection Common Structural Steel Terms Definitions Steel Joists Bolting Structural Steel Structural Steel Framing
SECTION G - TABLES
Concrete Form Design Tables Tap-Drill Sizes Linear Conversion Planks, Timber, Columns Modular Concrete Block Scale Common Mathematical Formulas
Page
271 278 293
295 297 299 302
303 304 305 306 325 329 334
339 344 345 346 349 350
ST022I 392
:**r
ST022I393
ST022I394
THERE IS NO SUBSTITUTE FOR COMMON SENSE
-2-
PERSONAL PROTECTION
STP22I395
1. Wear proper eye protection at all times (S-725)
a) Safety glasses and/or mono-goggles generally. b) Tinted glasses for burning and welding. d) Full face shield for grinding and chipping.
2. When working in high noise areas, chock need for ear protection (S-770).
3. Use respirator when cutting Transite asbestos cement. Use vacuum cleaner or other device to capture dust from saw.
4. Do not use any solvents in confined areas without adequate ventilation.
5. Wear hard hat at all times during working hours (unless variance has been obtained).
6. Wear proper gloves when handling lumber, cable and steel to avoid slivers.
7. Do not work on railroad right-of-way without permit from Railroad Department (S-760).
8. Do not work under suspended loads,
9. Do not work closer than ten feet to overhead lines without clearance from EDM (S-335) .
10.
Do not enter any vessel or pit without a Vessel Entry Permit (S--850).
-3-
11. Obtain roof access permit (via Job Planning Card) from Plant prior to entering roof area (S-735).
12,,
Always provide adequate ventilation when working in vessel, or pit. If using air mover, have it drawing air out of vessel rather than blowing it in.
ST022I396
13.
When working over water or other liquids, a life preserver must be worn except when working within permanently railed walkways or platforms.
14.
Eight inch high shoes or spats are required for burning and welding operations,
15.
Consider any liquid as a hazardous chemical until otherwise informed
16. Chemical Exposures (S--122)>
a) Speed is essential for treatment of chemical exposures. b) Flush with v/ater. c) Soap may be used. d) Call Emergency Service: Dial 1-2-3.
17.
Know location of eye and safety showers at your job location. Check them before starting j.ob.
6I2201S
-4-
EQUIPMENT
1. Check all chains, cables, ropes and hoists before using.
2. Do not wrap the load chain or cable of a hoist around a load as a choker.
3. Check all ladders for splits, broken rungs or other defects before using.
4. Do not use a drop cord unless there is a guard over
the bulb.
5. Hand tools
a) Keep burrs ground off all tool handles. b) Keep tools sharp. c) Never use tools with defective handles. d) Use the right tool for the job. e) Inspect all ropes before using.
6. Power Tools
a) Check need for a Hot Permit (S-900) before using power tools in production areas.
b) Be sure all guards are in place and operating properly.
c) Do not use electric tools without an equipment ground. Check grounds frequently.
d) Check with supervisor on need for CFI with portable electric tools.
ST0221398
-5-
d) When using air driven tools, be sure to make connection to an air source and be sure all connections between the source and tool are properly made,
d) Always use an excess flow valve ahead of any hose 5/8 inch or larger that is connected to an air-operated tool,
f) Concrete busters should be grounded unless it can be verified that there are no electrical lines buried in the area.
g) Protect any hoses or cords that must be strung across a vehicle or foot traffic area.
h) Use two men when using a 3/4 inch or larger drill motor.
7U Burning Equipment.
a) Always procure Hot Permit (S-900) before using torch outside of regular shops. Be sure sewer and manholes are considered on Hot Permit.
b) Know and follow proper start-up and shut-down procedures.
c) Do not use torch as a hammer.
d) Never leave torch or hose in vessel or pit except when in immediate use.
ST022I399
-6-
e) Do not lay an acetylene cylinder on its side.
f) Always support any compressed yas cylinder in the upright position and secure to prevent tipping.
g) Never take cylinders into vessel or pit.
h) Use Swedish Wool in ears to prevent sparks or slag from entering ear canal when burning or welding.
i) Do not move or transport cylinders without protector cap on.
j} Do not burn into pipes that have both ends closed.
k) Do not stand in front of gauges when turning pressure on.
l) Check hoses periodically for leaks.
m) Do not leave pressure on hoses when not in use.
8. When operating an electrical disconnect switch, stand to the right of the switch, turn face over right shoulder, and operate handle with your left hand in one quick movement.
9. For switches with handle located in the center of the cover, stand at the hinged side of the door, look away from the switch, and turn the handle.
00*11ZoOlS
-7-
WORKIHG IN ELEVATED POSITIONS
(S-810, S-630, S-750)
1. If workiny over seven feet above floor or ground, working surface must be railed or safety belt and lanyard must be used. Use lanyard to prevent fall rather than to catch you after fall.
2. If working from bosun chair or swing stage, you must wear a safety harness or belt attached to an independent line.
3,, Do not walk on Transite roofs without planking (S-735).
4. Folding scaffolds (upright) should not be erected over two lifts high.
5. Wood constructed scaffolds shall be constructed per S-810.
6. No device such as a crane or air hoist shall be used to raise or lower people unless it requires power to lower as well as to raise (no freefall).
7. Do not move scaffolds with people or material on them.
8. Do not work from straight ladder unless it is held by someone or is tied off.
ST022 11*0 I
-8-
GENERAL
L Housekeeping. a) Keep work area properly cleared. b) Keep tools and materials in their proper places. c) Keep materials covered whenever possible. d) Clean up job site when work is completed.
2. Bend nails over in any scrap lumber.
3. Obtain an underground clearance from Engineering before doing any digging or other underground work.
4. Barricade all floor openings sufficiently to prevent entry. If floor openings are covered, make sure covering is fastened to prevent movement.
5. Use hand lines to raise material or tools instead of carrying them up a ladder.
6. Use.hand lines or other suitable safety devices when cutting things loose and letting them down.
7. Be careful of valves and gauges if there is a possibility of bumping them with lumber, tools, etc.
8. Do not fill gasoline tanks with the motor running.
-9-
SAFETY STANDARDS INDEX
DOW CHEMICAL USA, MICHIGAN DIVISION
ST0221 ii02
S-UOl General Admmislrativc Safety Standard (11-3-76)
CHEMICAL
IOOSeries
S-l 20 Use of Cleaning & Degreasing Solvents (4-18-73)
S-l 22 Chemical Exposure (l-l 7-73)
S-l 29 Flammability Identification Symbols (3-1-77)
S-l 30 Storage & Handling of Flammable Liquids in Small Quantities (9-19-73)
S-131 Oxidizing Materials (9-25-63)'
S-135 Reactive Chemicals (10-18-72)
S-140 Asbestos (4-7-76)
ELECTRICAL
300Series
S-315 Electrical Grounding (5-3-77)
S-320 Lockout of Rower Driven Equipment (5-7-75)
S-325 Portable Lights for Hazardous & Semi-Hazardous Areas (8-20-75)
S-335 Power Line Clearance (3-21-73)
S-385 Temporary Wiring (3-6-74)
KQIHPM F.NT
400Series
S-400 Flexible Joints Used in Hazardous Service (4-7-76)
S-430 Guarding of Mechanical Equipment (9-20-72)
S-440 Sight Glasses (4-26-76)
S-450 Hand Rigging Equipment For Material Handling (6-20-73)
S-466 Roll Type Equipment (4-19-77)
S-468 Pressure Vessels (4-21-76)
S-477 Control of Radiation Hazards (1-1-72)
S497 Storage of Hazardous Chemicals in Refrigerated Storage Cabinets (4-5-77)
MATERIALS HANDLING 600 Series
S-620 Storage & Location of Gasoline Tanks For Refueling of Gasoline Fork Trucks and Similar Equipment (6-20-73)
-10-
S-622 S-623 S-624 S-625 S-626 S-627 S-630 S-64CI S-641 S-64S
Cylinder Regulators (5-1 7-72) Compressed Gas Cylinders (8-6-75) Proper l abeling, of Containers for Storage & Transfer (8-16-72) Dempster Tanks & Dempster Stations (3-6-74) Semi-Trailer Units (10-18-72) Power-Lift Trucks (8-15-73) Vehicle-Mounted or Supported Work Platforms (4-23-75) Loading & Unloading Tank; Trucks (3-1 5-77) Loading & Unloading Tank Cars (3-15-77) Pipeline Identification & F.mergency Plans (1-21-76)
ST022I403
MISCELLANEOUS
700-900 Series
S-700 Temporary Barriers (6-21-72)
S-7I0 Checking of Emergency Equipment (12-20-72)
S-715 Emergency Alarms (1-21-76)
S-720 Equipment Transfer (9-6-72)
S-725 Eye Protection (4-t 8-73)
S-730 Steam & Hot Water Hose (2-15-77)
S-735 Roofs (12-17-75)
8-740 D anger Bed Tag (4-19-72)
S-745 Respiratory Protection (10-6-76)
S-75Q Ladders (8-4-71)
S-760 Railroad Warning Signs (4-5-77)
S-765 Safe Drinking Water .(3-21-73}
S-770 Control of Hazardous Noise (4-19-77)
S-775 Line and Equipment Opeuing(IO-17-73)
S-800 Excavation for Construction and/or Maintenance (8-16-72)
S-S10 Elevated Work Platforms (4-19-72)
S-820 Distribution Emergency Response System (5-16-73)
S-850 Vessel Entry (1-31-77)
S-900 Hot Work Permits (8-4-76)
Safety Department kso 5-23-77
THE DOW CHEMICAL COMPANY ENGINEERING PRACTICES ARCHITECTURAL
-229-
DESIGN AID M3-452
Page 5 of 6
S0*i I 2201S
Spectra-glazed walls are used in lobbies, stair wells, toilets, lunch rooms, and locker rooms. They have been used in No. 690, No. 574, and No." 67S Buildings.
6.55 Gypsum Block Partitions'
Gypsum partitions are made of gypsum block size 30" x 12" and 3" or 4" thick. They are plastered on both sides to make a finished wall.
These partitions are relatively cheap, are light weight, and are easily installed.
This material should not be used where water or dampness is present,such as in toilet or shower partitions.
These partitions are suitable for office buildings only.
7.0 Steel Stud
7.1
Steel stud partitions have not been extensively used at Dow but are suitable for low cost fixed partitions using plaster or dry wall finish on steel studs.
7.2
Lath and plaster fastened on steel studs makes a good, strong, and fairly economical partition for offices. The thickness of walls can be varied to include pipes of various sizes, conduits, etc.
7.3
By using 5/8" thick sheetrock on both sides, it is possible to obtain a one-hour fire rating on the wall. Rock lath may be fastened to the steel studs with either screws or ratchet nails. These studs are made by Penn Metal Company, Inc., New York 17, N. Y.
7.4
Steel studs which will receive nails are also manu factured by Stran-Steel Division of Great Lakes Steel Corporation.
8.0 Movable Asbestos
8.1
Johns-Manville "Universal" asbestos panels. These panels are easy to erect and relocate. They consist of a wood
framed core, sealed and faced on both sides with asbestos cement sheets.
8.2
The panels are 1-3/4" thick and come in standard sizes and in standard colors. Door and window frames axe of metal. Space fot wiring is provided in the base.
90*ilZ201S
THE DOW CHEMICAL COMPANY
ENGINEERING PRACTICES ARCHITECTURAL
-230
DESIGN AID M3-4S2
Page 6 of 6
8.3
These partitions have been used in No. 433 and No. 672 Buildings and present a very good appearance. See catalogs for details.
8.4 Refer to manufacturer's catalogs for details.
9.0 Plastic Wall Tile
9.1
Plastic wall tile cemented to a concrete block wall give a very good partition to use in toilet, locker and lunch rooms.
9.2
The tiles are easy to clean and are inexpensive to repair or replace. The appearance is excellent as many colors are available.
9.3 The tile comes in 4" x 4'' and 8" x 8" sizes.
9.4
If the masonry wall is not smooth, give it one coat of plaster before installing the tile. A rubber cove base is generally used with plastic tile walls.
10.0 Steel Plate
10.1
These partitions are used for starter rooms in hazardous or semi-hazardous areas. The walls consist of 16 gauge
steel plate, seal welded to structural steel channel studs spaced at 2'-0 1/16" o.c.
10.2
The steel studs should be welded to steel supports at the fioor and the ceiling. The bottom of the steel wall sometimes rests on a Concrete curb 6" or 8" high.
10.3 See Drawing No. Cl-80841 for a steel plate, explosion proof, insulated wall as used in No. 637 Building.
10.4
All steel studs used in steel plate partitions should be spaced at 2*-0 1/16" to give a 3/16" joint for 6'-0" wide plates and 1/4" joint for 8'-0" wide plates.
10.5 6' and 8' plates are carried in Dow Stock.
9-25-68
0383
ci
l
DOW CHEMICAL U.S.A.
TEXAS DIVISION
prftport. t:xas 77541
ENVIRONMENTAL HEALTH REPORT
ASBESTOS MONITORING MAGNESIUM III B-800
c
F 11 F NO. BE - 1.702
niT; January 26 , 1979
AUTHOR P-* P1 Whatley
3- .3 . r_ _ _ _ _ _ _ _ _ _ _ yf
^ /
' / 77
rirncfTi k ^
CATE /97?
Summery
A. survey was conducted lo evaluate employee exposures to asbestos fibers during a plant shut down at Magnesium III, B-800, on November 28, 1978. All potential employee exposures were well within the permissible exposure limit.
Monitoring should be repeated during the next plant shut-down.
Employees should be informed of the results of this survey, and the informing documented.
</
I U U U j.^ 6 0
Diilf'Sulic-n
J. E. Grau li-815 A.. L. McDowell B-101
Toler R-815
L. U. Ratr.py 1803 Midland
R. R. Langncr 1603 Midland Marlene Swank 1803 Midland D. 3. Roberts 2020 Midland * F. P. Axe - Pittsburg * C. E. Halphen - Plaquemine * It. J. McCormick - Strongsville * Neil Murray - Sarnia * R. D. Olson 607 Midland * S. A. Goode - OCD
am oPcr>ATirs-a unit op the dow chemical company
Pile 33-1/02
r
C
January 26, 197!)
INTRODECTTON
At Che request of suoervisioti, a survey was conducted at Magnesium III, B-8O0, on November 28, 1978, Co evaluate employee exposures co asbestos fibers during a planned plant shut down for electrical repairs.
PROCESS DESCRIPTION
At Magnesium ITT, molten tiagn.Hsi.um is produced electrolvt lea I ly from mag nesium chloride in n hath of mixed 3n)l-?>. By-products of the process are chlorine, hydrogen chloride (both are removed by a vacuum system), magnesium oxide, water vapor, and cel) sludge. Magnesium chloride is fed to the calls via an automated conveyor system, and other salts are manually poured from bags into the cells. Vanadium pentoxide, an additive which increases cell efficiency, is added to the cells in sealed plastic bags. Molten magnesium is pumped from wells at the front of the cells into a crucible in the base ment, which is then transferred to cte casting plant.
Asbestos paper has two major uses at Magnesium III. It is used in small quantities (generally one piece at a time) when cells are being patched by the Running Repair Operators. A piece of asbestos paper is corn to cover die hole being patched while the employee takes a short break to cool off. The purpose of the paper is to keep the metal around the hole from freezing, and to keep Che cell sealed to insure that suction on the cell can be maintained. In general.a given Running Repair Operator patches cells about every two weeks.
Once or twice a year, the plant is shut down (usually two buildings at h time) for major electrical repairs. On chese occasions, several employees tear pieces of asbesLos paper to cover the netal wells and plug the feed and sueclou pipes. It takes 3-4 employees about au hour to cover the ceils in two buildings (approximately 00 cells), and from 1/2-1 hour to remove and dispose of the paper after repairs arc completed. The plant shutdown dearly represents the highest potential employee exposures co asbestos fibers, and is the procedure which was monitored in this study.
METHODOLOGY
Personnel samples were collected during both handling procedures (covering cells and paper removal) to determine employee exposures to asbestos fibers. The samples were eollectec by drawing a measured volume of air (approximate!y 1.5 liters per minute) at employee breathing zone height through aerosol filters (Kllliporn MAWG 937AO) with aendix Micronair II sampling pumps. The pumps were calibrated before and after use with a calibrated Brocks
rOCSmeter. Fibers were counted using Optical microscopy by Central Laboratory,
B-1225.
ST000326 I
Hit Ij8-L70?
c
January It, 1079
EVALUATION CRITERIA
Permissible exposure, limits (?EL's) ere concentrations of airborne substances to which nearly all employees may be repeatedly exposed through out a working lifetime without adverse effect. Moot PEL's are t iir.eweighted average concentrations for 3 to 12-hour work days and 40-hour work weeks. Permissible exposure limits do not represent Line lines between safe and dangerous exposures; they are based on industrial experience and experimental human and animal toxicological studies, and are intended toe use us guides lor plant design and for evaluating employee exposures.
The permissible exposure i.imir for asbestos fibers is two fibers per cubic centimeter of air (2 fibers/cc), as an eight-heur time-weighted average. An asbestos fiber is defined as a particle greater than or ecuai to five microns in length. Ten fibers/cc are allowed as a ceiling concentration for periods up to 15 minutes.provided the exposure for the entire 3-12 hour work day does r.ot exceed 2 fibers/cc, and there are r.o more than four excursions per day, which are separated by at least an hour.
RESULTS AND DISCUSSION
The results of the personnel monitoring for asbestos fibers are shown in Table 1. All potential employee exposures (nose-mouth respirators wece worn during the entire procedure) to asbestos during the handling procedures were well within the permissible exposure limit of two fibers per cubic centimeter of air. The highest potential exposure was about 202 of the allowed level; however, all others were 52 or less.
CONCLUSIONS_AND RECOMMENDATIONS
Employees at Magnesium til are not being overexposed to asbestos fibers. The highest potential exposures occur during plant shut downs once or twice a year, nr.d are well within the permissible exposure limit.
It is recommended that monitoring be repeated during the next plant shut down to further substantiate the results of this survey. Monitoring for asbestos fibers during cell patching procedures is noc necessary at this time.
It is also recommended that e:;tp-oyees be informed of the results of this survey, the consequences of overexposure to asbestos fibers, methods of control, and the care and use of respiratory protective equipment. Tills Informing process should be documented.
' ST0003262
F.HS EPW/bhs 1-26-79
' L ie :>3- 702
c
TABLE I ASBESTOS MONITORING RESULTS
SAMPLE NO.
BS-1702-1
2
3 4
5
6
EMPLOYEE MASTER NO 140319 133302 134916 135541 140319 135541
DATE
11-28-78 11-2.3-73 11-23-73 11-23-78 11-28-7-3 11-28-78
TIME (M!EX.)
45
50
-- 25 -- 17
ASBESTOS CONCENTRATION (FI3ERS/CC) 0.065 0.07 3 pump stopped 0.34
pump stopped 0.080
135541
11-23-78
36
8
140319
11-28-78
61
9
1411S0
11-2S-78
48
10
141298
11-28-78
34
0.040 0.044 0.09S 0.0C7
Permissible exposure limit { fibers/cc air)*
2
* 8 hour time-weighted average
Samples 1-6 represent cell covering procedures; 7-10 were collected during paper removal and disposal.
ST 0003263
f
COKSEDl'EKCES OF OVEREXPOSURE
COMPOUND: Asbestos
EXPOSURE LIMIT:
2 >5fibers/ml ,
microns in length
ODOR:
none
EYES:
Contact with the dust can cause irritation SIMILAR TO THAT CAUSED BY SIMILAR FOREIGN BODIES.
INGESTION:
Some evidence indicates that swallowed asbestos may increase chances OF STOMACH. . CANCER,
DUST INHALATION:
j
Short Term:
Inhalation of high concentrations
OF THE DUST MAY CAUSE MODERATE DISCOMFORT. INHALATION OF MODERATELY HIGH CONCENTRATIONS MAY CAUSE NO DISCOMFORT.
Long Term:
Inhalation of the asbestos fibers
IN CONJUNCTION WITH SMOKING HAS BEEN
SHOWN TO INCREASE,.CHANCES OF LUNG CANCER BY ABOUT DO TIMES THAT OF A
PERSON WHO NEITHER SMOKES NOR WORKS
WITH ASBESTOS. CAN ALSO CAUSE A (/~.
SERIOUS LUNG DISEASE CALLED ASBESTOSOS.
Can also cause cancer of the chesto
LINING,
o
CD .
. CO
COMMENTS: Proper respirator is required when working with1'0
asbestos.
EE!
DOW CHEMICAL U.S.A.
50983)/QYr,
TEXAS DIVISION FREFPOH r, TEXAS 77541
Sumttory
A survey was conducted to determine employee exposures to asbestos fibers while racking unqucnched ingots at Magnesium Casting B, R-842, during April, 1979. Employee exposures wore about IS of tho short term exposure limit, and less than 0.5% of the permissible exposure limit calculated as an 8 hour time-weighted average.
Further monitoring is not necessary at this time.
Employees should be informed of the results of this survey, and the informing documented.
bbs
Distribution
P. E. Howe B-837
K. T. Kerr B-837
A. L. McDowell B-10L File
'U' W. Rampy 1803 Midland \/R. R. r.angner 1603 Midland
Marlene Swank 1803 Midland , J. Roberts 2020 Midland F. D. Axe - Pittsburg C. E. Halphen -- Plaquetuine R. J. McCormick - Strongsville Neil Murray - Sarnia R. D. Olson 607 Midland S. A. Goode - OCD
AN OPEftATINC UNIT 0= THE DOW CHEMICAL. COMPANY
</->
lD
CO CO DO
TO-
B8-L818
2- June 1, 1979
INTRODUCTION
A survey was conducted to determine employee exposures to asbestos fibers at Magnesium Casting B, 3-342, on April 18, 1979.
PROCESS DESCRIPTION
Molten magnesium from Magnesium III is transported to Magnesium Casting B in covered crucibles, where .it is Then poured inco furnaces. The magnesium is pumped from the furnaces into molds on conveyors, and is allowed to cool in both air and water as the molds traverse the length of the conveyors. At the ends of three of the conveyors, the ingots are hand- or mechanicallystacked; a towmotor is used to remove and stack the large ingots from Lhe remaining conveyor.
Occasionally the magnesium ingots do not fall out of the molds into the water quenchers; as a result they fall under the conveyor as the molds turn upside-down while traveling back to the end of the conveyors to be refilled. Since these ingots have not been through the water quenchers, they are too hot to handle with the cotton gloves routinely worn by the Casting Operators while racking ingots, and asbestos gloves are worn
during the few moments necessary to retrieve and rack them.
METHODOLOGY
Since only a few moments are normally required to retrieve and rack the ingots which fall under the conveyors, a simulated procedure was used to determine the employee exposures to asbestos fibers ai these times. The water quencher was turned off on conveyor =4, and employees v.7earing asbestos gloves racked the hot (dry) ingots for periods of 10-25 minutes.
Fixed station and personnel samples were collected by drawing a measured volume of air (approximately 1.5 liters per minute) through aerosol filters (Millipore MAWG 937AO) using Bendix Micronair II air sampling pumps. The pumps were calibrated before and after use with a calibrated Gilmont rotameter (S/N B-2241). Sampline times ranged from about 10 to 50 minutes. Analyses were done by optical microscopy at Central Laboratory, B-1225. Sampling locations are shown in Figure 1.
EVALUATION CRITERIA
O
co 'O V-J ^
Permissible exposure, limits (PEL'S) are concentrations of air borne substances to which nearly all employees may be repeatedly exposed throughout a working lifetime without adverse effect.
File B8 --1318
-3-
June 1, 1979
EVALUATION CRITERIA (continued)
Most FEL's are time-weighted average concentrations for 8 to 12 hour work days and 40 hour work weeks. Permissible exposure limits do not represent fine lines between safe and dangerous exposures; they are based on industrial experience and experi mental human and animal toxicological studies, and are intended for use as guides for plant design and for evaluating employee exposures.
The permissible exposure limit for asbestos fibers is two fibers per cubic centimeter of air (2 fibers/cc), as an eight-hour time-weighted average. An asbestos fiber is defined as a particle greater than or equal to five microns ir. length. Ten fibers/cc are allowed as a ceiling concentration for periods up to 15 minutes, provided the exposure, for the entire 8-12 hour work day does not exceed 2 fibers/cc, and there are no more than four excursions per cay, which are separated by at least an hour.
RESULTS AND DISCUSSION
Monitoring results are shown in Table I.
Employee exposures to asbestos fibers while racking unquenched ingots are significantly below allowed exposure levels. The average employee exposure to asbestos fibers while racking was 0.1 fibers/cc air, substantially less than both the short term exposure limit of 10 fibers/cc air (for periods up to 15 minutes) and the permissible exposure limit of 2 fibcrs/cc air (as an 8 hour time-weighted-average) .
The average asbestos concentration in the area surrounding the employee (about 2 feet away) was approximately half of the average employee exposure, or 0.04 fibers/cc air.
1/7
--I O 03
C3
CL>
CONCLUSIONS AND RECOMMENDATIONS
-C
Employees at Magnesium Casting B are not being overexposed to asbestos fibers while racking unquenched ingots. Exposure levels are so low that the total employee exposure for racking a full 8 hour shift would be only 5% of the permissible exposure limit. Since racking unguenchcd ingots is not a routine procedure and the time involved is unlikely to exceed 15 minutes per shift, employee exposures are'actually closer to 0.5% of the permissible exposure limit (as an 8 hour time-weightedaverage)*, and 1% of the short term exposure limit for the few minutes spent actually racking.
* Calculated using the following equation:
8 hour average exposure = asbestos concentration x duration of exposure(hr) 8 hr.
File B8-1818
-4 June 1, 1979
CONCLUSIONS AND RECOMMENDATIONS(continued)
Further monitoring is not necessary at this time.
Employees should be inlormed of the results of this survey, the consequences of overexposure to asbestos fibers (attached) , methods of control, and the care and use of protective equipment. This informing process should be documented.
ehs
EPW/bbs 6-1-79
to --I <"D ;:o
CD
CD iNi
cn
BS-1S1S
TABLE I ASBESTOS MONITORING RESULTS
EMPLOYEE*/LOCATION
140613 141514 140613 141514
Average employee exposure during racking procedures
SAMPLE :/
B8-1818-1 B8-1818-6 B8-1818-7 B8-1818-10
ASBESTOS COHC EtITSATl ON (FIBEaS/CC AIR) .064 .094 .16 '
.12
.11
On conveyor - to left of employee On conveyor - to left of employee On pallet - behind employee On pallet - behind employee On pallet - to left of employee On pallet - to left of employee
Average area concentration
-2 -5 -4 -9 -3 -8
.045 .048 .018 .066 .032 .048
.042
Short terra exposure limit (periods up to 15 minutes) - 10 ibers/cc air Permissible exposure limit (S hour time-weighted average) - 2 fibers/cc air
ST9Q03276
* Master numbers are shown for the employees monitored
Fib >% - \m
Figure l
Asbe^los sampling loca-Kons, 12 - ^2,
*
0*
*4
CorWe^o r
t/i --i CO CD
CD
CO
ro
'-j --i
r SOirnpIc. (oca.-lnons
O employee pobj-Kon
CONSEQUENCES OF OVEREXPOSURE
COMPOUND: Asbestos
EXPOSURE LIMIT;
2 >5fibers/ml ,
microns in length
ODOR:
none
,
.
EYES: `
Contact with the dust can cause irritation SIMILAR TO THAT CAUSED BY SIMILAR FOREIGN BODIES.
INGESTION:
Some evidence indicates that swallowed ASBESTOS MAY INCREASE CHANCES OF STOMACH
CANCER.
DUST INHALATION:
Short Term:
Long Term:
Inhalation of high concentrations
of the dust may cause moderate
DISCOMFORT. INHALATION OF MODERATELY HIGH CONCENTRATIONS MAY CAUSE NO DISCOMFORT.
Inhalation of the asbestos fibers
IN CONJUNCTION WITH SMOKING HAS BEEN,
SHOWN TO INCREASE CHANCES OF LUNG
CANCER BY ABOUT 90 TIMES THAT OF A <Lo
PERSON WHO NEITHER SMOKES NOR WORKS ro
WITH ASBESTOS. CAN ALSO CAUSE A
SER-IOUS LUNG DISEASE CALLED ASBESTOSES.
Can also cause cancer of the chest
LINING.
;
COMMENTS:
Proper respirator is required when working with asbestos.
r-
50983
DOW CHEMICAL U.S.A.
TEXAS DIVISION FREEPORT, TEXAS 77541
ENVIRONMENTAL HEALTH REPORT
Summary .A survey was conducted from November, 1979-January, 1980 to determine
employee .exposures to chlorine and asbestos.
All employee exposures were within acceptable levels.
Future monitoring emphasis should be placed on short term or peak exposures to employees while performing those :ob procedures with the highest potentials for exposure.
Employees should be informed of the results of this survey and the informing documented.
if*
--4 O
CT
O cn vo CTV
bbs
0! stribution D. E. Billings A-5024 /.. E. Flake B-101 0. N. Hollis A-1201 K. L. Johnson A-5024 File
L. W. Rampy 1803 Midland R. R. Langner 1603 Midland Marlene Swank 1803 Midland * F. D. Axe - Pittsburg * C. E. Halphen - Plaquemine *R. J. McCormick - Strongsville * R. D. Olson - Sarnia * S. A. Goode - OCD
AN OPERATING UNIT OF T*<. COW CHEMICAL COMPANY
File A50-1950
2 July 14, 1980
INTRODUCTION
A survey was conducted November, 1979 - January, 1980 to determine employee exposures to chlorine (Cl_) and asbestos at Chlorine VI, A-5000.
PROCESS AND JOB DESCRIPTIONS
Chlorine is produced electrolytically from sodium chloride brine in asbestos drawn diaphragm cells. By-products are hydrogen and 8-10% sodium hydroxide (cell effluent). The chlorine is cooled to condense and remove water,, and is further dried by bubbling through concentrated sulfuric acid. The dry chlorine is then compressed and liquefied, stored in spheres, and piped to Dow user plants or to Chlorine V for shipment to outside customers. The electrolytic cells are fabricated and repaired on site, but the asbestos drawing is done by the Cell Services Department. Brief summaries of the job duties of Chlorine VI employees follow:
Superintendent and Engineers - most of their time is spent in the A-5024 office, with 15-25% in the cell area, brine and liquefaction plants.
Shift Foreman - generally spend 75% of their time outside in all threeplants.
Production Foreman - spends an average of 50% of his working time outside in the three plant areas, balance in office.
Maintenance Foreman - usually outside in plant areas 60% of time.
Cell Repair Foreman - work in the A-5022 shop except during turn-arounds, at which time virtually all of their time is spent in the cell areas. Turn-arounds usually occur every 1-2 months.
Control A Operators - operate the board in the control room, and are seldom outside unless problems in the plant develop.
Control B Operators - work in the liquefaction plant, generally spending 5 0% of t-he shift out in the plant. Also responsible for collecting quality control samples of concentrated sulfuric aid (completely slickered plus respiratory protection).
ST060696S
File A50-1950
3 July 14, 1980
PROCESS AND JOB DESCRIPTIONS (continued)
Control C Operators - "Cell Operators" who spend the majority of their time in the cell areas. Collect & analyze chlorine and cell effluent samples, as well as brine as it comes into the block from Chlorine I. Also pulp cells with wet asbestos slurry from the Cell Services Department..
Control C Operators - Brine Plant - much time is spent out side collecting grab samples of brine and carb liquor (sodium carbonate). Also responsible for waste water treatment in that area.
Class 1 & Class 2 - Cell Repair - erect and dismantle cells in cell areas. Clean & rebuild cells in the cell repair shop(disassemble, remove graphite, scrape off putty, wash down, and replace graphite & putty(cathodes are further cleaned at cathode cleaning facility at Dow Oyster Creek).
Class 2 Unloader- unloads asbestos slurry, sulfur dioxide, sulfuric acid ("98%), and sodium thiosulfate tank trucks. Checks cell effluent (sodium hydroxide), chlorine, and carb liquor (sodium carbonate) pipelines for leaks, and cleans & greases chlorine & cell effluent valves. Also runs a diesel engine and changes air conditioning filters m A-5024. Generally spends 60-70% of his workday outside in various areas of the plant.
Jr. Assistant Chemist, Class B - collects chlorine sample from CDC '{cooling, drying & compression) area; spends majority of time analyzing chlorine, brine & sulfuric acid samples.
METHODOLOGY
Personnel chlorine and asbestos samples were collected by E. A. Engeling of Chlorine VI. )3endix BDX44 Super Sampler pumps were used to collect chlorine samples on 5 gram charcoal tubes, and asbestos on Millipore'; fillers (MAWG 037AO, Millipore Corp., Bedford, Mass.). The samples were collected by drawing a measured volume of air (approx. 1.5 liters per minute) through a Millipore filter together with a charcoal tube in line for six hours. The Bendix pumps were calibrated before and after use with a calibrated Gilmont rotameter, S/N B3895. Sampling was conducted while employees performed routine job duties.
Analyses for chlorine were performed by Analytical Services, B-2406 by extraction of the charcoal with sodium hydroxide and potentiometnc titration for total chloride ion content. The chloride content was doubled to obtain the total chlorine content. Analyses for asbestos were performed by Analytical Services, B-1225, using optical microscopy.
9969090 IS
File A50-1950
4 July 14, 1980
EVALUATION CRITERIA
Permissible*exposure limits (PEL'S) are concentrations of air
borne substances to which nearly all employees may be repeatedly
exposed throughout a working lifetime without adverse effect.
These levels are based on industrial experience, and on
experimental human and animal toxicological studies. Permissible
exposure levels do not represent fine lines between safe and
dangerous exposures. As the name indicates, they are to be
used by Industrial Hygienists as guides for plant design and
for evaluating occupational exposures. PEL'S for gases and
vapors are usually expressed on a molar volume basis as parts
contaminant per million parts of air (ppm); for dusts, mists,,
aerosols and fumes, they are usually expressed as milligram or ,
microgram of contaminant per cubic meter of air- (mg/rn and ug/m ,
respectively).
For asbestos fibers, PEL'S are expressed as
asbestos fibers per cubic centimeter of air. An asbestos fiber
is defined as a particle greater than or equal to 5 microns in
length.
Most PEL'S are time-weighted average concentrations for 8-12 hour work days and 40 hour work weeks. For many substances,' higher Short Term Exposure Limits (STEL's) are allowed for periods up to 15 minutes, provided that there are no more than four excursions per day with at least 60 minutes between exposure periods. Ceiling PEL'S are designated for some substances, in which cases short term exposures to higher levels are not permitted.
The PEL's for chlorine and asbestos are as follows:
Chlorine Asbestos
8 Hour Average 1 ppm ceiling 2 fibers/cc air
STEL 10 fibers/cc
ST0606967
RESULTS AND DISCUSSION
Chlorine VI employee exposures to chlorine and asbestos are summarized by job classification m Table I; individual employee exposures are shown in Appendix A. Contractor Maintenance employee exposures are summarized in Table II, and are shown individually in Appendix B.
All employee exposures to both chlorine and asbestos were within allowed exposure Levels.
Average employee exposures to chlorine by job classification were 30% or less of the allowed exposure limit, with the highest average exposures being those o: the Control C Operators. How ever, actual employee exposures ranged as high as 70% of the allowed exposure limit; in these cases employees may have received short term or peak exposures in excess of the allowed 1 ppm. Average employee exposures to asbestos were less than 1 % of the allowed exposure Liin.t.
Pile A50-1950
5 July 14, 198U
CONCLUSIONS AND RECOMMENDATIONS
Employee exposures to chlorine and asbestos at Chlorine VI are well within acceptable levels.
Future monitoring for chlorine and asbestos should be conducted with emphasis on short term or peak exposures during those job procedures with the highest potentials for exposure.
Employees should be informed of the results of this survey, the consequences of overexposure to chlorine and asbestos (attached), methods of exposure control, and the care and use of protective equipment. This informing process should be documented.
ST0606968
EHS
EPW/bbs
7-14-80
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File A5Q-1950
APPENDIX S
CONTRACTOR MAINTENANCE EMPLOYEE EXPOSURES TO CHLORINE AND ASBESTOS (8 HOUR AVERACES) CHLORINE 6
EMPLOYEE
EMPLOYEE NO.
Foreman Pipefitter
Welder
7370
8846 3735 3801 9791 4656 4208
7995
Carpenter & Pipefitter *
Fiberglass Work Electrical Foreman Electrician
* Machinist
Janitor
15783
17840
171
850 3597 428 3367 3494 533
145 049
014
EMPLOYER
DATE
2m>
U.S. Cont.
II l It II rt
It
l-j-80
1-3-80 12-31-79 1-4-80 12-31-79 12-31-79 1-4-80
1-4-80
0.13
0.06 0.06 0.05 0.03 0.06 0.07
0.16
1-3-80
0.09
If
l-J-30
0.09
0-lf States
II ft ft <V It ft
1-9-80
1-9-80 1-7-80 1-7-80 1-9-80 1-7-80 1-7-80
0.07
0.15 0.10 0.07 0.07
' o.ii
0.06
MIt cGill Maine.
1-4-80 1-10-80
0.11 0.20
Ramirez
1-10-80
0.15
ASBESTOS (FIBERS/CC AIR)
.012
.006 .011 .011 .007 .016 .014
too dirty to count
.012
. ccuac rty tc
.016
Oil .016 .012 .015 .020 .002
.004 .002
008
ST060697I
NOTE: Filters "too dirty to count" represent normal welding or glass fiber work no asbestos handling involved.
File A50-1950 EMPLOYEE
Class 2 Operator(contl.)
Sr. Asst. Chemist Class B
APPENDIX A (continued)
MASTER NO.
DATE
ci2(ppm>
130801 142123 142130 141622 138397 133775 139063 138305 138517 138449 139188 142128 137390 131677 139765 138473 138825 142124 136236
107860 142168
12-19-79 L2-13-79 12-13-79 12-13-79 12-14-79 1Z-3-79
11-29-79 12-14-79 11-30-79 12-7-79 L2-20-79 12-13-79 12-14-79 12-6-79 12-21-79 12-6-79 11-29-79 12-7-79 12-20-79
1-10-80 12-27-79
0.04 0.05 0.05 0.06 0.05 0.27 0.17 0.10 0.19 0.08 0.21 0.04 0.09 0.44 0.05 0.25 0.15 0.04 0.07
0.12 0.02
ASBESTOS FIBERS/CC
.015 .009 .014 .017 .017 .016 .011 .007 .017 .015 .002 .014 .015 .012 .016 .012 .012 .013 .011
.008 .014
ST0606912
HOTE: Filters "too dirty to count1* represent normal welding work -- no asbestos handling involved.
File A50-1950 EMPLOYEE Welder Control A Operator
Control A Operator Control B Operator Control C. Operator
Class 1 Operator Class 2 Operator
APPENDIX A (continued)
MASTER NO.
DATE
C12(PPM)
ASBESTOS
._____________________________________________________ FIBERS/CC AIR
117055
115435 134071 116142 142033 141582
130122 110304 113814 115122
134880 137377 138177 136698
138003 142129 139770 138835 -138866 "136251 133621 137301 141492 131902 134864 135085
136252
139655 138181 142126 138985 132824 137632 142421 135143 139239 140712 139240
1-2-80
12-3-79 11-28-79 11-26-79 12-27-79 12-28-79
12-4-79 12-11-79 12-17-79 11-27-79
11-28-79 12-5-79 12-12-79 11-26-79
11-26-79 1-2-80 12-4-79 12-17-79 11-27-79 12-4-79 12-11-79 12-4-79 12-20-79 12-28-79 12-4-79 12-5-79
12-7-79
12-20-79 11-30-79 11-30-79 12-7-79 12-14-79 12-14-79 12-7-79 12-6-79 12-13-79 12-6-79 11-29-79
0.07
0.22 0.16 0.11 0.05 0.03
0.18 0.06 0.07 0.23
0.36 0.27 0.04 0.14
0.19 0.13 0.34 0.21 0.36 0.25 0.06 0.70 0.31 0.05 0.25 0.22
0.06
0.05 0.06 0.18 0.10 0.08 0.08 0.06 0.45 0.04 0.27 0.15
too dirty count
.006 .005 .005 .013 too dirty count.
.010 .009 .003 .406
.013 .002 .006 .006
.004 .004 .006 .008 .003 .005 .008 .006 .010 .009 .014 .006
.013
.014 .017 .016 .012 .011 .016 .008 .016 .015 .007 .005
ST0606973
FILE A50-1950 EMPLOYEE
APPENDIX A
EMPLOYEE EXPOSURES TO CHLORINE AND ASBESTOS (8 HOUR AVERACES) CHLORINE 6
MASTER NO.
0ATE
C12(PPM)
Prod. Supc. Sr. Prod. Engineer
Prod. Engineer Engineer Prod. Foreman Foreman
Rotatins Shift Foreman
-
Instrument Technologist Instrument Technician Inse. Trainee Material Control Clerk Prod. Clerk Machinist Pipefitter
132154
138154 506930 138898
138576
141912 142251
131719 113835
132330 137945 104582 115399 134255
119051 137536 119459 135208 134962
133521
140002 131433
140342
100744
132572
136674
131795 134847 132378
12-12-79
12-11-79 L2-17-79 12-3-79
12-12-79
12-3-79 12-17-79
12-12-79 12-19-79
12-19-79 12-19-79 12-21-79 12-3-79 12-19-79
12-21-79 12-12-79 12-27-79 12-28-79 1-9-80
12-5-79
12-17-79 12-5-79
12-5-79
12-20-79
12-11-79
12-27-79
1-2-80 12-21-79 12-23-79
0.07
0.14 0.06 0.23
0.05
0.22 0.04
0.09 0.06
0.04 0.06 0.11 0.26 0.24
0.01 0.07 0.16 0.35 0.07
0.24
0.07 0.24
0.26
0.07
0.09
0.04
0.05 0.05 0.09
ASBESTOS FIBERS/CC
.006
.008 .014 .015
.007
.003 .007.
.307 .012
.309 .007 .017 .008 .017
.004 .005 .004 .008 .007
.011
.003 .005
.012
.007
.003
.013
.011 .013 .009
ASBESTOS/BRICKMASONS
ASBESTOS/CARPENTERS /H ASBESTOS/INSULATORS ASBESTOS/SALVAGE
^
I. TESTING SCHEDULE
A. Audiograms - Annually if the 3-hour equivalent for noise exposure is greater than 85 decibels for 8 hours,
B. AM Blood Work (to include CBC, UA, liver and renal function tests) - annually.
C. Stools for Occult Blood over age 40 - annually.
D. Chest x-ray, expirogram, respiratory sympLomology history annually, '
E. Sputum cytology over age '40 or with greater than 10 years potential exposure - annually.
F. Core Exam - Every 2 years.
G. Hands on physical examination every 2 years over 40 years of age and every 4 years under 40 years of age.
II. JUSTIFICATION FOR DEVIATION FROM THE CORE EXAM
A. Audiograms - Conforms with Dow guideline Cor hearing conservation.
B. Annual'AM Blood Work and stools for occult blood - Dictated by tradition.
C. . Annual chest x-ray, expirogram, and respiratory history Dictated by the Asbestos Standard published in the Federal Register, Volume 40, No. 197, on Thursday, October 9, 1975.
D. Annual Sputum Cytology - Dictated by tradition and the Asbestos Standard. (The Standard states age 45, but traditionally it has been offered to those over age 40.)
E. Physical Exam - Dictated by tradition. To deviate from this tradition would probably have a detrimental Impact on participation and attitude, toward our periodic health surveillance program.
ST0582823
CKB/ske
10-16-80
PROTOCOL FOR HEALTH SURVEILLANCE OF THE PLANT A 6 B CARPENTERS
PROBLEM
l. These individuals are potentially exposed to asbestos and thus are covered by the Asbestos Standard published in the Federal Register, Volume AO. No. 197. on Thursday, October 9, 1975.
2. The Dow guideline for hearing conservation states that audiograms are to be done annually if the 8-hour equivalent for noise exposure is greater than 85 decibeLs. According to the noise survey dated February 19, 1981, there is potential for exposure to noise in excess of 85 decibels.
METHOD
1. Add an annual health history, expirogram, and chest x-ray for all individuals who work with asbestos in addition to the Core examination every two years to comply with the Standard. Also, add a physical examination based on age. Those over 40 years of age will be examined every two years and those under 40 will be examined every four years. This is to look for additional signs of possible disease or cancer. )
2. Add an annual audiograin.
INTERPRETATION OF RESULTS
The history and all tests will be evaluated individually for each employee. The group will be analyzed for trends or changes in symptomo or signs of respiratory disease,If these exist. The audiograms will be analyzed for trends to facilitate hearing conservation.
DISSEMINATION OF RESULTS
The results of all tests will be individually communicated to each employee in writing. Any significant abnormalities will be discussed with supervision ar.d a representative of Environmental Health Services. There will be no further dissemination or publication of the results vlchout a separate approved protocol.
8T0582822
Sr. Industrial Physician
CKB/ske 2-16-82
K. A. Fishbeck, M.D. Medical Director
J. R. Venable, M.D. U. S. Are* Medical DirucLur
STATISTICAL EVALUATION OF RESPIRATORY SYSTIM INDICATORS AMONG INSULATORS
Introduction
This report presents statistical findings developed from an epidemiologic study
of insulators employed by the Texas Division of The Dow Chemical Company. The
report does not include a literature review or a medical interpretation of the.
results. These crucial elements of a study are properly left to the industrial
physician responsible for the health of these workers.
The objectives of the statistical evaluation were: (1) to identify through per
sonnel records all employees who worked as insulators at the Texas Division;
(2) to determine the current status of these workers and the dates of their em
ployment as insulators; and, (3) to examine the relationship between exposure
duration and several respiratory system indicators, namely the number of morbidity
episodes due to diseases of the respiratory system, the number of deaths due to
respiratory cancer and two respiratory function measures, the forced midexpirat
flow (FEF25_75%) and the forced expiratory volume at three seconds (FEV-j).
The insulator craft has existed since 1941 at the Texas Division. Between 1941
and 1971, seventy-two men who worked as insulators were identified through per
sonnel lists. As of August 1971, the status of these workers was as follows: Total--------------------------------------------------- 72
Still Working For Texas Division Active Insulators --------------- 29 Not Active As Insulators - 1
30
Released From Company ------------------Retired -----------------------------------------------
29
9
Transferred From Texas Div. ---------
2
I2 6 Z 0 0 O is '3
Two factors which pose limitations on the statistical analysis are evident from the above tabulation. These factors are: (1) the rather small size of the' exposed-
co risk population (72 men), and, (2) the large percent of these employees released
from employment (40%).
" f>-
2- -
Methcdology Seniority lists for the insulator craft which were available through the Personnel Department were reviewed to identify the population-ac-risk. Since insulators participated in the periodic health exam program, a double check of the population was possible. The verification procedure revealed that the seniority lists had provided complete and accurate icentification of the population. The work history card for each in-scope employee was examined to determine the date of birth, the current status of the employee, and the dates during which the employee worked as an insuLator. Years-on-job was subsequently used as an indicator of relative expo sure levels.
Morbidity Data Morbidity episodes are recorded in the employee's medical record. The date of the episode and the physician's diagnosis arc listed for each event. Extracting this information was most time consuming because of the need to pull individual records and the unedited nature of the data. Since no priur use of these data cor statistical
--t purposes is known to the author, it was necessary to assume that the completeness^ of reporting and quality of the information was adequate. Morbidity data for thep^
UO exposed-to-risk population were abstracted beginning in 1960. The number of epigqjjes
CO by cause and the frequency of episodes per 100 work-ycars-at-risk were tabulated for the total insulator population. A. matched pairs design was used to compare the mor bidity experience of the insulators with that of a suitable control group. In this case, the control group was selected from Power Departnent employees. Resources were conserved by restricting the comparison to the 24 insulators who worked con tinuously from 1960 through July 1971 versus 24 Power Department employees of the same age. These employees also worked continuously during the observation period. The pairing procedure eliminated the need to take into account the age of the worker or the period of observation in comparisons between the two groups. Until such time that routine data processing of morbidity data is initiated, the matched pairs type
of analysis will remain the most efficient way to statistically treat morbidity,data."
-3-
Spircmetric Measurements
Spirometric measurements or insulators were provided through the periodic health
exam program. The most recent testing for each insulator was selected for analysis.
Readings were available for 42 insulators. Two measures, the FEF25_75% and the
FEV3, were selected for analysis. The age and height, as well as smoking history,
were obtained for each insulator at the time of his exam. Because of several
limitations, three categories--nonsnoker, current smokers of at least one pack per
day, and all others,--were used to describe the smoking history for each worker.
The objective of this phase of the study was to determine if the two respiratory
function measures, corrccced for age, height and smoking history, were related to
years-on-job. Age and height corrections for the*. FF.V3 were based on "Guides To
The Evaluation of Permanent Impairment - The Respiratory System" (1965). A factor
of .95 was used to adjust FVC readings to FF.V-j readings. Age and height corrections
for the FEF25_75JJ were obtained from "Spirometric Standards Tor Healthy Nonsmoking Adults" by Morris, et al (1971)'! The FEF25_75 readings were dichotomized according
to the sign of the deviations from predicted norms to simplify the analysis. Mortality Data
CO
6?6?000 I
The mortality analysis was based on copies of death certificates received by the
Company Group Insurance Department as proof of death. Individuals released from
the Company, excluding retirees, are lost to any mortality study based strictly
on insurance records. The potential biases introduced by this loss of information
have been discussed in the literature. The control group for the mortality com
parisons consisted of a cohort of 6500 Midland location hourly workers followed
between 1954 and 1969. The expected numbers of deaths were calculated based on
mortality rates for the cohort population, adjusting for age by the indirect method.
Results
Morbidity Analysis The overall morbidity experience for insulators from 1960 to August 1971 is sum
marized in Table 1. As expected, episodes related to diseases of the respiratory
system account for over forty percent of the total absences due to sickness.
Table 2 shows a comparison of morbidity experience between insulators and Power
Department employees. The between individual range in the number of total episodes
(0 to 20) indicates the wide variability in utilization of group insurance benefits. There are no statistically significant differences at the .05 level between the two
groups. This is true both with respect to total episodes and with respect to episodes
due to diseases of the respiratory system.
Spironetric Analysis
Table 3 shows the average deviations of FEV3 readings from predicted norms by years of exposure. . No significant association at the .05 level was found between years
of exposure 3nd FEV3. Adjustments for smoking history had little effect on the re
sults. The scatter plot of individual FEV3 deviations from predicted versus yoarson-job is shown in Figure I. In contrast. Table 5 indicates that nonsmokars perform near predicted norms and about .4 liters better than the average cf either of the ^
two smoking groups. Similar results are obtained for the percent of FF.?25_757 q
readings below predicted norms.
CD Thus, smoking history was found to be related to CD
fV>
respiratory function performance while, years on the job was not. The possible CO
effects on these readings of selection biases, such as population attrition, are ^
unknown.
Morrality Analysis Table 6 summarizes the mortality findings of the. study. The observed deaths among
insulators is less than expected in each category of comparison. However, since
the exposed-to-risk population is relatively small and the period of observation
is short, the favorable experience to date does not, in itself, insure similar
results 11 the future.
Sutanarv The statistical evaluation was carried out along the lines set forth in the Introduction of this report. While the necessary data were indeed available, they were sometimes a burden to gather. This was especially true when they had been microfilmed. With regard to the insulators, no evidence was found to indicate an association between years on the job and the respiratory system indicators which were investigated. The many qualification statements which appeared in the report attest to the fact that the data were collected under real world and not laboratory conditions.
Table 1. Episodes Of Morbidity Observed Since I960 Among 46 Insulators Actively Employed As Of 1960.
Cause All Causes
Diseases of the Respiratory System Accidental Injuries Diseases of the Digestive System Diseases of the Circulatory System Diseases of the Genito-Urinary System Diseases of the Nervous System
and Sense Organs Infective & Parasitic Diseases Diseases of the Musculoskeletal System
& Connective Tissue Neoplasms - Total Endocrine, Nutritional & Metabolic Diseases Mental Disorders Diseases of the Skin & Subcutaneous Tissue All Other Causes
Number Of Episodes 166 70
20
18
14 14
8
7
7 4 -- -- -- 4
Number Of Episodes Per 100 Person Years At Risk 39.1 16.5 4.7 4.2 3.3 3.3
1.9 1.7
1.7
.9
-- --
.9
ST0002932
Table 2.
Comparison Of Morbidity Episodes Occurring Between January 1960 And July 1971 For 24 Insulators Paired With 24 Power Department Employees Based On Age.
ST 0002933
Pair Number
Total Episodes____________________ P.asoiratorv Episodes Insulators Power Deoi.Emu1. ; Insulators Power Dcdc . F.mn 1.
1 2 17
0 10
2 07
04
3 80
50
4 56 5 34
01 00
6 3 20 7 62
28
31
8 25 9 75
13 53
10 2 0
11 4 4
20
30
12 6 3 13 2 5
20 10
14 2 0
10
15 1 1 16 3 4
00 11
17 6 12
18
18 10 7 19 11 5
72 24
20 6 1
30
21 8 2
5 1.
22 3 3
11
23 6 2 24 4
31 13
Tota 1
110
123
Number or Epi- 40.0
44.2
sodes/100 Person Years At list
49 17.6
51 -------- TO--------------- --
Table 3.
Mean FEV.. Readings Expressed As Deviations From Predicted Norms By Exposure Group, Adjusted And Unadjusted For Smoking History.
Exposure Groim < 10 Years
10 - 19 Years 20 - 29 Years
Average Exposure
Years
3.1
16.1
24.5
Number of
Hen
8
17
17
FEV3 In
Adjusted For Smoking Kistorv
Liters
Unadjusted For Smoking His torv
-.13
-.13
-.28
-.34
-.19
-.14
Table 4.
Percent Of EEF5-75% Readings Eelcw Predicted Nora By Exposure Group, Adjusted And Unadjusted For Smoking History.
Exposure Croco < 10 Years
10 - 19 Years 20 - 29 Years
Average Exposure
Years
3.1
16.1
24.5
Number of
Men
8
17
17
% Of EEF25-75/I Bc^ow Predicted Norm
Adjusted For Smoking History
Unadjusted For Smoking Histcrv
38 38
42 47
38 35
ST0002934
Table 5.
Mean FEVj Readings Expressed As Deviations From Predicted Norms And Percent Of FF.F25_73v Readings Below Predicted Norm By Smoking Category.
Smoking Category
Nonsmokers Current Smokers Of At Least One Pack Per Day
All Other
Number of
Men
10
13 19
Deviations Of FEV^ In 7.iters From Pre dicted Norms
+.09
% or fef25_75%
Below Predicted Norms
10
-.32 -.31
46 53
Table 6. Observed And Expected Deaths Among Insulators By Interval Since First Exposure
Interval Since First Exposure
Total Less Than 20 Years More Than 20 Years
Years Exposed To Risk
942.1
806.2
135.9
Total Deaths Observed Expected
2 4.4 2 2.7 0 1.7
Deaths Due To Respiratory Cancer Observed Expected
0 .3
0 ,2
0 .1
ST0002935
FIGURE I. SCATTER PLOT OF DEVIATIONS IN FEVj FROM PREDICTED VERSUS YEARS ON JOE FCR 42 INSULATORS (ADJTUSTED FOR SMOKING HISTORY)
DEVIATIONS OF FEV-, FROM PREDICTED
THE DOW CHEMICAL COMPANY
T C X A> S CIVISIQN FREePOftT TCXA3 773*1
May 13, 1968
R. L. Buell B-1201
RE: Insulators
We have done annual periodic examinations on the insulators since 1960. The examination is directed primarily to the lungs and consists of chest x-rays, ventilatory measurements (pulmonary function) hematocrit, ECG, and examination of heart and lungs by a physician.
The concern of the Union about the welfare of their men is a just one and has come about probably because of the wave of cases that lias hit the medical literature recently. The incidence of the usual type lung cancer is much higher in asbestos workers who smoke - the smoking and asbestos expo sure seem to be additive. There is an unusual type of cancer effecting the lining of the chest and abdominal cavities called mesothelioma which is due to asbestos exposure. Any asbestosw worker's death due to mesothelioma would be con sidered due to asbestos exposure until proven otherwise.
I appreciate Mr. Kinsel's concern about whether the insulators are being examined periodically but I gather from the tone of his letter that he is not concerned from a humanitarian view point.
As a matter of interest one of the union agents for the insu lators stated he heard a talk by a physician at a union meeting which seemed out of place judging from the words of this union agent. The talk seemed to be a scare-type talk and was either misinterpreted by the audience or misinformation was given out.
I hope this may be of help to you.
REF:mr
R. E. Flake, MM. D. Industrial Maaddicine
ST05832 15
ST00I4088
Page 1
FOREWORD
The Dow Chemical Company is made possible by the combined efforts of every employee, by the use of capital and equipment furnished by stock holders, and by the patronage of customers who buy our products. This great enterprise will be successful if these three groups are well served and to whatever degree we understand one another.
The employee is entitled to advance as much as possible, receive courteous and fair treatment at all times, and work with the surrounding conditions maintained at the highest possible standard.
The stockholders are entitled to a fair return from their investment. It is the duty of all em ployees to protect this investment by the proper use and care of equipment, by elimination of waste, and by giving a fair return for wages received.
The customer must receive as much or more for his money than our competitors can give if our business is to be permanently successful.
To accomplish these things in the fullest meas ure. a real challenge is continually before each and every employee.
PURPOSE OF THIS BOOK
This book is presented to you as a basis for friendly understanding. It is hoped that it will prove to be of mutual benefit, and a contributing factor in creating and maintaining harmonious relations between you, your employer, and your fellow workers.
ABSENCE FROM WORK
Every employee should think enoueh of his job to promptly notify his superior when it is necessary to be absent. This is only asking good business practice. Starting January 1, 1941, all unexcused absences in excess of one regular work period will be investigated.
Employees will be discharged for failure to report for work for three consecutive working days unless the employee notifies his superior or the Employ ment Department and receives permission for ab sence from work.
Page 2
ASSIGNMENT OF WAGES
In all cases where an assignment of wages involv ing an employee is served on The Dow Chemical Company, the employee will be automatically dis charged for cause.
BADGES
An hourly employee when hired is furnished with two badges so that it will not be necessary to change badges from street clothes to work clothes. The small badge must be in plain sight on your outer garments when you pass through the clockroom. Pay checks are given to employees only when they are wearing their badge. In case of loss, badges will be replaced at a cost of $1.00 each: this is deducted from your pay check.
CLEANLINESS
It is the duty of all Service and Construction Crews to clean-up after completing their work. Remove all the litter and scrap to places provided for the same, and turn the equipment back to the Production Department in a workmanlike manner.
Workmen are particularly cautioned to conform to special practices in various places to guard against the contamination of products. The use of a little grease or oil in the wrong place can spoil a valuable product.
By the practice of cleanliness every employee can contribute a great deal in promoting the sale of our products. Many prospective customers visit our plant. The appearance of equipment, aisles, and work benches, and the cleanliness and attitude of all employees are very important factors in helping to favorably impress such visitors.
DELIVERY SERVICE
Express delivery service is maintained from the Stockroom to all parts ot the plant. Learn the service available from this system before making yourself subject to criticism by calling personally for items of stock.
GRIEVANCES
In case an employee has a grievance it should first be presented to the foreman for settlement. If
Hage 3
no satisfactory answer is given, the grievance should be taken to the superintendent. Any com plaint not settled in this manner may be taken up with the Employment Manager, who will present the grievance to the management.
ST00I409I
HOLIDAYS
Six holidays are observed as follows:
New Year's Day San Jacinto Day Independence Day
Labor Day Thanksgiving Day Christmas Day
INSURANCE
Metropolitan Life and Health and Accident In surance paying $1700.00 upon death and $14.00 per week for up to 13 weeks during disability result ing from sickness or accident has been made available to all employees at a cost to them of 84c per month, the balance of the cost being borne by The Dow Chemical Company. The $1700.00 life in surance benefit is paid to your named beneficiary upon your death, regardless of cause, while the weekly sickness and accident benefits are paid when you are disabled from causes not connected with your employment.
Benefits are payable after the seventh day of disability. It is your responsibility to contact the Employment Department for the necessary blanks and instructions needed in filing your claim.
A large number of insurance checks, both large and small, have been received by employees or their families since this insurance plan was first offered, and the benefits of the plan have been proven.
LAUttOEAT SEEvYVCE.
Wear clean clothing. Laundry service for the following personally owned cotton work garments
is free: Work pants Work shirts Overalls Jackets
Coveralls Shop Coats Shop Aprons Shop Caps
There is danger in dirty greasy clothing, and certain chemicals may cause irritation or damage
to the skin. Frequent washing of garments removes these 1
LOANING OF COMPANY TOOLS
NO COMPANY TOOLS ARE LOANED FOR PERSONAL HOME USE. Adequate tool rooms and loan service are provided throughout the plant to supply employees with special tools: such tools are charged to the employee by tool checks or loan slip method. Tools lost or broken by work men are charged to their account, when it is felt that such toss or breakage is the result of careless ness or negligence.
MAIL
All personal mail should be addressed to your home and not to you in care of the company. For your convenience the company will handle out going mail if deposited in any one of the various department mail boxes. All first class mail received at the main office will be opened and the receiving date stamped thereon.
PAY DAYS
You will be paid by check on the Sth and 20th of each month for time worked prior to 8 :00 a. m. on the 1st or 16th. respectively. Checks are available after 3 :00 p. m. on pay days.
PERSONAL TOOLS
Personal tools may be taken for home work by a pass out card issued by stock room department.
Removal of personal tools belonging to employees who have been released is executed the same way. Department heads are asked to cooperate fully in this regard by giving the Stockroom Department sufficient notice in all cases of release.
PLANT RULES--BULLETIN BOARDS
Any changes in or additions to Company rules or general instructions will be posted on departmental bulletin boards before the rules or instructions are to take effect.
All notices of departmental or general interest must be approved by the department superintendent before being posted.
Page 5
SMOKING
SMOKING IS PROHIBITED AT ALL TIMES IN CERTAIN PLANTS.
In plants where smoking is prohibited. NO SMOKING signs have been posted on all building doors, or to include specific areas.
Employees violating this regulation will be auto matically discharged.
SOLICITATIONS
No solicitation of any kind will be permitted within the plant or offices of the plant, unless the same is authorized by the department head and approved by management and conducted under the supervision of the department head.
SUGGESTIONS
THE COMPANY WELCOMES SUGGES TIONS FROM ANY OF ITS EMPLOYEES AND ALWAYS APPRECIATES CONSTRUCTIVE CRITICISM.
TIME CLOCKS
Every employee of The Dow Chemical Company, including the President and General Manager, has a time card and rings it regularly. No exception to this rule is made. Employees are positively for bidden to ring tor each other. Ringing late will not be tolerated. You are expected to be at your place of work a few minutes before the whistle blows.
USE OF COMPANY AUTOMOBILES
Drivers of company cars must conform to all rules and regulations pertaining to the same. The maximum speed limit within the plant is twentyrive miles per hour. All signs must be observed.
It is not permissable for passengers to ride on the outside of cars. The maximum number of passengers in the driver's seat is two besides the driver.
Use the company car the same as you would vour own.
*160*110 0 1 S
Page 6
USE OF TELEPHONE
During working hours the use of the telephone for personal calls cannot be extended to employees. However, urgent incoming messages will be de livered.
Quite often urgent messages are received at the plant at times when workmen are off duty: therefore, it is important for workmen to report changes of address to their foreman and the Em ployment Department.
WASTE
Compressed air costs money; the required amount of air (5c per 1,000 cu. ft.) for two shops is 300 cu. ft. per minute. A few leaks could double this requirement and also make it impossible to reach the best working pressure. Watch for and report all leaks.
Provision for strict observance of economy in light must be planned and carried out by the fore man. Definite responsibility must be placed or assumed by the foreman to avoid wasting of light.
Water is so much used that it is very easy to misuse. Equipment requiring water cooling is quite often found shut down after the work shift but the water is left running.
Industrial wastes cause losses of millions of dollars yearly; most of it could be stopped. Your attitude toward waste is very important. You are more valuable, as an employee, if you help prevent waste.
WORKING HOURS--OVERTIME
1. The work-day shall begin at 8:00 A. M. and end at 8:00 A. M. on the following day. The work week shall begin at 8:00 A. M. on any Monday and end at 8:00 A. M. on the following Monday.
2. Time and one-half will be paid for all work done on the following holidays: Xew Year's Day, San Jacinto Day, Independence Day, Labor Day, Thanksgiving Day and Christmas.
V 3. Time and one-half will be paid for all work done in excess of 8 hours in any work-day except
STOOI 4096
ST0OI4097
V.FETY
set forth the nt of (Texas )any and to practices and hile studying ith the probh any other There is no :an make re-
L--
D
nt to be concompany, but The practice ety measures, all dependent npioyees must eatest part of
g Things
Page 11
Take safety seriously. Be as good about protect
ing your fellow workman as you would about
helping them if they were hurt. It is kinder and
more profitable to all.
1
I COMPENSATION
1
l
<
The Dow Chemical Company operates under the
Workman's Compensation Law of the State of
Texas in settlement of all claims for personal in
juries of employees arising out of and in the course
of their employment with the company. L'nder this
act an employee who is so injured will receive com
pensation at the rate of sixty percent of his weekly
wage, but not more than $20.00 per week nor less
than $7.00 per week for such time as he is unable
to work. This payment starts on the eighth day
of incapacity following the date of injury. If inca
pacity continues for four weeks or longer, the first
week's compensation is also paid. Various standard
ized schedules have been incorporated in the law
in regard to the length of time for which compensa
tion shall be received for total, or partial, tempor
ary or permanent disability. During the first nine
ty-one days after the injury the employer furnish
es reasonable medical, surgical and hospital service.
All matters pertaining to compensation are handled by the Employment Department.
FIRST AID
It is the policy of the Company to maintain, for the benefit of its employees, the best possible First Aid facilities. The First Aid room is located at the garage. 901 building. The Department is sufficiently equipped to handle emergency first aid cases. The personnel includes four graduate nurses. There is a nurse on duty twenty-four hours a day.
The First Aid is maintained solely for you: con sider it your duty to use it at any time for even the slightest injury received while at work.
It is considered to be in order to call at the First Aid for relief treatment for minor AILMENTS NOT ATTRIBUTABLE to your employment, when such treatments will permit you to complete your
Thinkl Ii It Safe?
ST00I4098
STOOI 4100
Page 1"*
therefore, are asked to read them carefully. After you have read and studied the booklet, sign the printed statement on the last page and return it to the Safety Department.
GENERAL RULES
1. While no attempt will be made to set up definite procedures in case of a serious accident, the following general rules should be studied as a guide:
(a) The ambulance and First Aid phone number are in large letters on the cover of the phone book. Call the ambulance immediately. Call the First Aid as well, so that the nurse on duty may call for help if needed.
(b) Be calm and explicit. Deliver the message so that there is no chance for a mistake. Be sure to give the building name, the build ing number, and the type of accident.
(c) Unless specific instructions have been given you what to do--remove the person from further danger, make him as comfortable as possible, and make sure that there is no danger from exposure.
(d) In moving an injured person to a place oi safety, extreme care must be exercised as there may be fractured bones. Move the patient as little as necessary.
(e) In cases of bad acid or caustic burns, flood the burned area with water--and lots of it-- and get the patient to the First Aid. Running water is far better than just immersing the burned area.
2. It is hereby declared to be a rule of The Dow Chemical Company, that WHENEVER AN EMPLOYEE RECEIVES AN INJURY. EVEN THOUGH IT BE CONSIDERED SLIGHT. HE MUST REPORT AT ONCE TO THE FIRST AID STATION. If the foreman or crew leader is present, the injured employee shall advise him of the injury before reporting to the First Aid; but it the fore man or crew leader is not present, then the injured
We Need Your Help in Preventing Accidents
ST00I4I02
Page 16
5. Horse play, scuffling, throwing things, and fooling with compressed air in the plant are dan gerous and will not he tolerated.
6. Few men realize the danger in the use of compressed air. The air hose should never be directed toward an individual.
Before using compressed air, as an aid to re moving dust from clothing, the equipment used for the purpose must meet the approval of the Department of Safety.
7. Personal cleanliness is an important item in the maintenance of healthy and safe working conditions:
(a) Always wash up before eating--particularly if you have been handling paint, lead, or chemicals.
S. Watch the Safety Bulletin Boards. Each poster is a lesson in itself; you can easily profit by reading it.
9. When you see a warning or danger sign, be sure you are safe before going ahead. Not to do so is to invite injury.
10. Boards with nails sticking up must not be left lying around. When you see such boards, turn them over, pull the nails, or put the boards where they can do no harm.
11. Do not climb through, under, over, nor be tween railroad cars. Wait until the train passes, or walk around the end of the train. With the exception of the engine or switching crew, no one is allowed to ride yard locomotives or freight cars.
12. Do not attempt to lift or push objects which are too heavy for you--ask for help when you need it. Learn to lift the right way to avoid strains: bend your knees, keep your body erect: then push upward with your legs. It is much easier and safer.
13. When working on any kind of a pressure line be sure that the supply is shut off and a warning sign placed on the supply valve. Never open or close a valve on a pipe line unless you know it is safe to do so.
Practice Safety Yourself--Other* Will Follow You
STOO I 4 10>*
Always BendYour Le os
14. All excavations, open manholes, and other places where persons might fall must be protected by suitable railings and lights.
15. When walking on plant roadways walk on the ieit hand side ni tiie road, unless paths or walks are established.
16. The speed limit in the plant tor all com pany and private cars or trucks is twentv-ftve miles per hour. This limit must not be exceeded.
17. The driver of a company car. truck, or taxi is responsible for the condition of his car while it is entrusted to him. Any irregularities of brakes, lights, horn, fumes in cab. or general operation of the automobile must be reported to the garage on the regular form provided for the purpose. It is requested that drivers ot plant cars keep on the roads designated for travel and refrain from driving on areas not designated for car traffic as nutch as possible.
Good Housekeeping is Good Safety
Page 18
18. Pickup trucks carrying passengers must be equipped with the standard seating arrangement. The Service Department is responsible for seeing that new pick-up trucks are so equipped before be ing issued to individuals or departments.
19. if your work requires you to enter other departments, familiarize yourselves with the rules and dangers of these departments.
GOGGLES--CLOTH ING
1. Goggles or face shields must be worn as pro tection on the following jobs:
(a) While working on or around magnesium cells.
(I>) While working with or pouring molten metal.
(c) On any grinding operation.
(d) On any chipping operation--goggles only. (e) Breaking up concrete or brickwork--goggles
onlv.
NATIONAL
SAFETY
COUNCIL
Wear Safe Shoe*
Page 19
(f) Any welding or burning operation.
(g) When the handling of chemicals is particu larly hazardous.
2. You are required to wear goggles when and where you are instructed to do so. For the safety oi your eyes do not neglect to do it. Protect your eyes when working near welding equipment.
3. Where the heat is excessive, men are advised to wear sweatbands on the forehead to keep per spiration out of the eyes. Anti-fog sticks may be secured from the Safety Department. A small amount applied to goggle lenses will prevent steam ing. Goggles should be adjusted to fit the face com fortably. Head straps should fit over the tops of the ears and well down on the back of the neck.
4. You are especially cautioned to roll up your sleeves, not wear a necktie, and not wear gloves while working around any revolving machinery.
5. Rings, watch chains, key chains, loose jack ets are all potential accident makers and should not be worn in the shops or around moving ma chinery. The results from an accident caused by one of these factors are often extremely serious.
0. If you are working where there are heavy fumes or dust you will lie required to wear the respirators provided tor your protection.
TOOLS--EQUIPMENT
1. Safety devices and guards are tor your pro tection. Keep them in place at all times. Removing or tampering with safety guards is forbidden by law.
1. In using grinder--lie sure that the tool rest is within one-eighth of an inch oi the wheel and that guards and hood provided are in proper posi tion and in good repair. Wear goggles for all grind ing work, unless the grinder is equipped with an approved glass shield.
3.Stop machinery to clean, oil. adjust or repair by pulling the main switch. Lock the switch or hang a' warning sign on it if there is a hazard due to someone starting the equipment heiore it is ready.
You Can't See Through a. Gl*m Eye
TOO I 4 j 06
cn
L OMlIOOlS
hings, and it are dan-
the use ot never be
aid to re>ment used >val of the
irtant item ie working
particularly u. lead, or
ards. Each asilv profit
;er sign, be .'ot to do so
lust not be >oards. turn >ards where
er. nor berain passes, . With the ew, no one "reight cars. ijects which in you need oid strains; : then push r and safer.
a pressure off and a alve. Never unless vou
Follow You
11. Keep the floor space around machinery as clean and as free from obstructions as possible. Loose material, oil. and grease are all definite hazards in any location, particularly >o around machinery of anv kind.
1. Never stand or walk under a crane load. Obey the man handling the load from the floor;
We C*n Furnish Goggles, But Not Eyes
STOO14108
Page 22
listen tor the crane horn or other signalling tievice. When entering a shop floor, over which there is a crane, look for the crane--determine its loca tion before crossing the floor.
The responsibility of carrying a load safely is placed upon the crane operator. You must hook your load to his satisfaction at all times.
2. Riding a load handled by a crane or riding crane chains or slings is strictly prohibited with the exception of crews working on steel erection.
3. The practice of moving oxygen or acetylene cylinders, by means of cradling one or more cylin ders in the crane chain, is strictly prohibited. Gas cylinders are not to be hoisted or lifted, under any circumstances, by crane except in specially con structed holder.
4. Certain men are designated as crane oper ators. Xo one other than these operators are to operate a crane except in case of emergency and with the permission of the Shop Superintendent.
5. Do not leave a load hanging or hooked on. Make sure that everyone is out from under load, lower and place load, unhook immediately and hook up chain or remove sling. See that hook or chain is hoisted above head level immediately after unhooking.
<> After finishing any repair work, make sure that all tools and materials are removed from crane or track.
7. Xo employee is allowed to work under a sus pended load without same being blocked in such a manner that any failure ot crane or part would not allow load to fall on him.
ELEVATORS
1. In case any elevator equipment is found out of repair, the Machine Shop Office must be notified at once. Do not try to repair the elevator yourself.
2. All elevator gates are to be in a closed po sition--except at the level at which the elevator
A Good Safety Record it a Fine Recommendation
; "
ignalling dewhich there line its loca-
ad safely is i must hook es.
ne or riding hibited with ;1 erection.
or acetylene more cylinihibited. Gas d, under any lecially con-
crane oper ators are to .ergency and perintendent.
hooked on. under load,
ediately and .hat hook or .diately after
. make sure moved from
under a sused in such a rt would not
is found out st be notified itor yourself.
a closed pothe elevator
smmendation
Page 23
car is standing. If the gates do not close auto matically, do not consider that as an excuse for leaving them up.
3. Do not allow material, rubbish, stock, etc., to accumulate near elevator gates. The space directly in front of the elevator shaft must be kept clear at all times.
4. When doing any repair work on elevators of any type--close and lock, or tag, the main switch.
5. The following definite rules apply to the use of the various man elevators in the plant:
(a) When you step onto the elevator--grasp the handle with one or both hands and face the belt.
(b) When shutting the elevator off, after reach ing your floor, make sure that no one is riding the elevator at the time.
(c) No material or tools are to be carried on the elevator which cannot be easily and safely handled with one hand. No hand tool or material over 18 inches in length is to be carried.
(d) The practice of placing tools, tool boxes, or material of any kind on the elevator steps--to be carried to a higher or lower level--is strictly prohibited.
(el Report to your foreman, or the Safety De partment. any hazardous conditions around the elevator landings.
LADDERS
1. Never use a ladder which is defective in any respect, such as with broken or split side rails or rungs. The tool room is equipped to renew broken rungs with rung replacers.
2. In placing ladders--the best angle at which to lean the ladder is that in which the horizontal distance from the foot of the ladder to the base of the wall or beam against which the ladder is resting is one-quarter of the length of the ladder.
Think How Much Suffering First Aid Prevent*
S T 0 0 I4 I10
*" .j.
I II11001S
IS
NCIk
ver night, tie ery floor unely anchored iy is holding boxes, tools.
hands when se a rope, or : both hands cing outward. iers in aisleblind corners. I ot you ele-
head in case ily. in
Page 25
WELDING EQUIPMENT
1. Never look at an electric arc with the naked eye. When observing or w'orking near arc welding operations--the eyes must be protected from direct exposure.
2. Heavy canvas (or metal) screens must be used to afford protection to all others from elec tric welding wherever possible, particularly when welding is being done in the shop.
3. When welding wherever there is the least chance of causing a fire, keep a fire extinguisher within reach. Welders are required to have a quart hand extinguisher as a part of their equip ment.
4. Gas motor driven portable generators or air compressors must not be located inside build ings. The exhaust vapors are extremely dangerous and these machines must be operated out of doors.
5. Never allow oil or grease in any form to come into contact with part of the oxy-acetylene welding equipment. An explosion may occur if you violate this rule.
6. Use extreme care in handling gas cylinders. Do not drop tanks over steps, off of trucks or platforms.
7. Keep cylinders away from salt and other corrosive chemicals and fumes.
8. Carrying or lifting tanks by crane or hoist is absolutely forbidden, unless a sling or cradle constructed for this purpose is used--see Cranes --3. page 22.
9. Put nothing on top of tanks--you may damage the safety plug or regulator, or interfere with the quick closing of the valve. Valves must be closed when cylinders are not being used.
10. Cylinders must be secured to prevent their being knocked over while in use.
11. All cylinders should be protected against excessive rise of temperature. On storing cylinders in the open--see that they are protected against extremes of weather.
Report Every Injury
r
i4STOO j 12
Page 26
12. Foremen and welders should study thor oughly the more detailed "Safety Precautions for Arc and Acetylene Welders."
13. The Boiler Shop is equipped to service and repair all acetylene welding equipment. Worn and defective gauges, regulators, etc., must be turned in for repair.
ELECTRICAL EQUIPMENT
1. There is no line of work where it is more necessary to be always on the alert for danger. Do not take chances.
2. Do not fail to report any electrical trouble whatsoever, or any apparently dangerous install ations, to your foreman.
3. Employees not authorized are forbidden to work or tamper with any electrical wire or equip ment.
4. Treat all circuits, so far as possible, as if they are alive, even though you believe them dead.
5. In handling live or control parts on circuits such as are exposed on switches, switchboards, etc., use only one hand if possible. When closing a switch, close it solidly and abruptly. This will greatly reduce the chance of the switch "arcing".
rt. Electric wires which seem to be unused or are hanging free are sometimes charged and are dangerous. Report them but do not touch them.
7. When opening a switch, in order to shut down a machine for maintenance or repair work, the switch must be property tagged with a warning or do not start sign. When the work is done get the proper authority to start the equipment.
8. Get the voltage off the line--in case of any electrical fire. Open the switch or circuit breaker, or call the power house to have the switch opened on that line.
9. In case of fire on or near electrical equipment, do not use water to extinguish the lire. Proper extinguishing units of C-O-Two or Pyrene are lo cated near all large electrical machines.
Foot Note--Remove Natl* from Boards
cudy thorautions for
service and Worn and be turned
T
it is more for danger.
ical trouble rous install-
'orbidden to re or equip-
ssible, as if e them dead. s on circuits iwitchboards, Vhen closing lv. This will tch "arcing".
r tintieprl or
*ged and are ouch them. to shut down ir work, the a warning or done get the t. i case of any rcuit breaker, switch opened
cal equipment, ; fire. Proper 3yrene are loles.
t Boards
10. In case of severe electrical shock--remove the person from the source of current immediately and call the ambulance and First Aid at once.
(a) Use a dry coat, dry rope, a dry stick or board or any other dry non-conductor to move either the victim or the wire, so as to break the electrical contact.
(b) If the victim is conducting the current to ground and is convulsively clutching the live conductor, it may be easier to shut off the current by lifting him than by leaving him on the ground and trying to break his grasp.
(c) Open the nearest switch if that is the quick est way to break the circuit.
11. Accidental electric shock usually does not kill at once, but may only stun the victim and for awhile stop his breathing. Under these circum stances artificial respiration is recommended im mediately.
FIRE PROTECTION
1. In case of fire--call the Dow operator and report the fire, giving building name and number and location of fire. In cases of fires after regular working hours, the watchman will notify all pro duction and service men directly affected by the fire.
2. Learn the location and proper use of the fire fighting equipment in your department.
(a> Do not use water where extinguishers are provided.
^b) Xever hang up an extinguisher. If you have used one or see one which is not on a hook, notify the Pipe Shop at once.
(c) Use extreme caution in fighting hot fires in closed rooms or badly ventilated areas. Toxic products of combustion often provide a ser ious hazard.
3. The plant fire department is under the super vision of the Pipe Shop. All maintenance of fire fighting equipment, automatic sprinkler systems,
Safety and Efficiency Go Hand in Hand
ST00 I 4 I 14
?
Page 2A
r *-
ST 0014115
lire hydrants, and fire hose is taken care of by that department. Notify the Pipe Shop at once if any of the above equipment is not in perfect working order.
4. Never pile any material on any floor beyond its load limit or to a height within less than eight een inches of the level of any sprinkler head.
5. Except in times of immediate use. aislewavs, passages, stairways and elevator approaches must be kept clear; a closed passage might result in the loss of an entire plant. There must he unrestricted passage to all fire hose and fire protection equip ment at all times.
<>. Keep the places around you clean. Put all oily waste, rubbish, or papers in the covered containers provided for that purpose.
7. Do not work on any electrical apparatus or wiring unless it is part of your work.
Double Your Caution in Rain, Snow or Sleet
Page 29
8. Some plants of The Dow Chemical Company are a definite fire hazard because of the materials handled. These particular plants are prominently posted with signs prohibiting smoking and the carrying of matches while in or around the build ings and requiring the personal O. K. of the plant superintendent before doing any welding in or around the plant--look for these notices and obey them to the letter.
9. When doing any welding--use extreme cau tion in lighting the torch and make sure that the hot slag will not fall where there is danger of its igniting inflammable material. Welders are re quired to have a hand extinguisher as a part of their equipment.
VNCIk
:are of by that once if any of rtcct 'vorkin^
. floor beyond :ss than eightikler head. use. aislewavs, proaches must it result in the je unrestricted uectiou equip-
an. Put all oily :red containers
l apparatus or
ow or Sleet
9! MllOOiS
1
Piec .!')
LABORATORY SAFETY
The importance of safe practices in all laboratory work or handling of chemicals cannot be overem phasized. While the previous sections of this book let apply to laboratory workers as well as to others, the following instructions must be kept particularly in mind. Your laboratory director or supervisor is aware of the importance of safety and will welcome your suggestions.
GENERAL--HANDLING CHEMICALS
1. Keep all bottles labeled. Serious accidents have resulted from neglecting this simple pre caution.
2. Know the materials with which you are work ing so that you are able to handle them properly and caution others in their use.
3. Deposit waste chemicals in crocks or jars provided for the purpose. These waste jars must be emptied daily.
4. IN THE CASE OF A CHEMICAL BURN --IMMEDIATE FLUSHING WITH WATER IS THE BEST EMERGENCY TREATMENT.
5. Keep goggles or a face shield on hand and use them on any 'Hazardous operation. Remember, it is YOUR eyesight which is being protected and accidents usually happen when least expected.
6. Aisleways and approaches to apparatus and lire equipment must be kept clear so that quick exit is unhampered.
7. Guard your apparatus with suitable glass or metal shields so that those nearby are safe. Men working near one another on different projects are not aware of what each may be doing.
8. Read carefully the specific safety instructions for your particular laboratory. Each man must realize his individual responsibility for the safety of himself and others.
A safety minded person is a valuable asset to
V plant and community
ed
tor ta 3.
locatit quantity safety i
4. mg lines of! use. In 1 tainers throughj of cable
Don't 1
STOOMil 17
iboratory overem-
his bookto others, .rticularly ervisor is
welcome
accidents iplc pre-
ire workproperly
; or jars s must be
L BURN \TER IS N'T.
hand and emember. ected and cted. -atus and hat quick
glass or .ate. Men ojects are
structions tan must he saietv
**et to
Make sure yon understand the relationship be tween your job and the available equipment before you begin work. Your immediate superior or the Safety Department will be glad to answer any questions you may have.
1. Low boiling flammable liquids should be heat ed with steam whenever possible.
2. Extreme care must be used when distilling flammable liquids. Look over any nearby equip ment for open flames, electric heaters or open re lays. any of which may provide a source of ignition for flammable vapors.
3. Flammable liquids must the stored in a safe location in metal containers except when small quantities are to he used immediately. Regulation safety cans are available for this purpose.
4. De careful to avoid static electricity in pump ing or transferring flammable liquids. Metal tanks, lines or other equipment should be grounded beiore use. In transferring flammable liquids, both con tainers should be grounded either by contact or through the use of battery clips and a short length of cable.
Don't let familiarity with your job make you forget safety
S T 0 0 I4 I18
%
PaRC 12
PRESSURE EQUIPMENT
1. When working with pressure apparatus, make sure of the temperature and pressure for which the equipment has been designed.
2. Always work with a safety factor of at least two over hydraulic tests made on pressure equip ment. Under unusual conditions a greater safety factor may be necessary and the choice of equip ment must rest upon an individual who has had such authority delegated to him. Be certain the strength has not changed due to corrosion or high tempera ture use since the last hydraulic test.
3. Conform to recommendations in the use of frangible disc safeties.
4. Make sure you are not exceeding allowable w'orking pressures on the pipe and fittings being used.
5. The volume of a pressure vessel must be considered carefully in relation to the volume and possible expansion of the material with which you may be working. In general a pressure bomb should not be filled to more than six-tenths of its capacity. High temperature operation will reduce this figure.
6. When opening pressure equipment, do not remove any nuts or bolts on the closure before first loosening all closure fastenings. Make sure the closure is free, releasing any pressure, before removing any bolts or nuts completely.
7. NEVER ATTEMPT TO REMOVE OR BLOW OUT EQUIPMENT OR PIPING WITH OUT FIRST BEING POSITIVE THAT ALL IN TERNAL PRESSURE HAS BEEN RELIEVED OR THAT YOUR FACE AND EYES HAVE BEEN ADEQUATELY PROTECTED. DO NOT DEPEND UPON GAUGE READINGS TO IN DICATE LACK OF PRESSURE.
NEGLECT OF THIS SIMPLE PRECAUTION IS THE GREATEST SINGLE CAUSE OF CHEMICAL ACCIDENTS. IF THE ACCI DENT RESULTS IN PERSONAL INJURY YOU ARE THE ONE TO BLAME AND THE ONE TO SUFFER.
Your job is only as safe as you make it
S T 0 0 I4 I19
ST006739
Biochemical Research Department THE EDW CHEMICAL COMPANY
Sub.lect: INDUSTRIAL HYGIENE SURVEY OP VARIOUS OPERATIONS AT THE CHLORINE CELLS, BLDGS? 261, 19b, 1^7, 295. 236,
270, 303, 207.
Pile T34.21-21-3(E\)
Chg. 1219 Rec'd. 5/7/48
'
Pin'd. 3/20/51
Work by H/ Hoyle
E. J. Schneider
to:
I. F. Harlow, Bldg. 309 (l) R. M. Hunter, Bldg. 261 (l) W. R. Perry, Bldg. 261 (l) Medical Department (l)
Att: H. H. Gay, M. D., Bldg. 256 Safety Department (l)
Att: S. M. MacCutcheon, Bldg. 401
0 v/Vr/
THIS REPORT !5 THE PSOPcRTf OF
THE OCR CHEMICAL COMPANY
SUMMARY AND CONCLUSIONS
1. Significant amounts of chlorine, sufficient `to cause,
inflammation and swelling of the respiratory system from short
periods of exposure, were found in areas where men were working
on and among tie chlorine cell series. 2. Hen working in these areas have been getting by without
severe exposure by using respirators, however, it must be kept in
mind that excessive amounts of chlorine above the maximum allowable
concentration of 1 p.p.m. for an-eight-hour exposure do exist among the cell series.
3. No excessive amounts of chlorine were found in the
making of bleach solution at the cell brine plant, 3^5 building.
4. Excessive concentrations of chlorine occurred in the
loading of ton cylinders with liquid chlorine when the delivery
line became plugged and insufficient time was taken to purge the
connecting lines to the cylinder before removing them.
DOW-2904
,
i^iuLUCuauai.
i/epcLi*uueu
T34.21-21-3
Page 2
5. No exce33ive amounts of chlorine were found during the
normal loading of cylinders and no odor of chlorine was noticed
during normal operations to purge, test and load tank cars.
6. Excessive amounts of chlorine and sulfuric acid were
found while dumping the sulfuric acid drying tower to the sewer.
7. No excessive amounts of alkali dust were found among
the chlorine cell series. .
8. No significant amounts of mercury vapor were found at
the discharge of the vacuum pumps for the mercury arc rectifiers.
9. Excessive amounts of pitch dust must be considered to
exist, since men who are working at the pitch grinding operation
do become photo-sen3itized and must limit their outdoor activities.
ST006740
10. Large amounts of graphite dust were found during the
loading of plates into the buckets to be impregnated with phenol
formaldehyde resin solution. Since the loading operation involves
only an hour or so, the exposure to the graphite dust can not be
considered excessive.
11. The graphite dust concentrations found in the machine
shop were well within the limits for an inert dust.
12. The worker U3ing the band-saw wa3 found to be exposed
to more fine du3t than workers at the other machines, possibly
because there was no spot exhaust ventilation provided.
13. No excessive amounts of formaldehyde or phenol vapors
were found during the making of the phenol formaldehyde resin or
during the various drumming operations.
, oxocueuixcax ness avail xieparttnent T34.21-21-3 Page 3
14. The millions of particles per cubic foot of air of asbestos
was found to run higher than the maximum allowable concentration of 5
for an eight-hour exposure for the handling of dry asbestos in cover
ing the cell diaphragms. Since the exposure occurs only eighteen
times a day for a short period with a total exposure of less than
two hours, the amounts of asbestos found cannot be considered excessive.
CHLORINE
I. Significance of Chlorine Exposure
:
1. For many years a gas concentration of 1 p.p.m. (by volume)
has been used as a standard for evaluating workmens' exposures.
Recently there has been some expression of opinion that 2 or 3 p.p.m
9 0 0 1 S 'I
could be tolerated up to 8 hours daily without adverse effect. Gas
concentrations much above 3 p.p.m. unquestionably produce irritation
e (tissue injury) to the eyes, nose, and throat; concentrations above
10 p.p.m. may cause serious effects on single relatively short expos-
. ures. Beginning at about 3 p.p.m. chlorine causes unmistakable pain
in the eyes, nose and throat to which very little tolerance develops.
Thi3 painful action serves a3 an excellent warning of the presence
of harmful concentrations of gas. There appears tc be no evidence of
chronic effects from repeated exposures at concentrations of less than
2-3 p.p.m. (concentrations having no immediate acute effects). Repeated
exposures above 2-3 p.p.m., however, tr.ay maintain an irritation of
the eyes and respiratory passages, produce an erosion of the teeth,
and possibly a nonspecific debility.
TjV.21-21-3
Page 4 2. To a large extent the data of Table I, II, III, and IV merely give numerical expression to what has been apparent by sensory perception and experience, that excessive gas concentrations are encountered rather frequently if not routinely. Considering the nature of the operations and that much chlorine comes from unpreventable or accidental leaks, it may not be practical to reduce these concentrations of chlorine. Accordingly,' it is necessary to emphasize the need for proper respiratory protection, the training of workmen, and the provisions for handling leaks. The results emphasize the desirability of medical examinations to assure the workmen are receiving adequate personal protection. If the men show no evidence of Injury that is persistent or frequent, then our principal additional recommendation is that every opportunity to lessen chlorine contamin ation be utilized. II. Observation and Presentation of Data 1. The odor of chlorine was ever present throughout the cell buildings and from time to time it was noticed that the men were required to use their respirators in order to gc about their work. 2. Air samples were collected at several locations and on different days. The results of the air analyses are collected in Table I and II and can be compared with the accepted maximum allowable concentration of 1 p.p.m. for an eight-hour exposure.
7ST00 G 1| 2
Biochemical Research Department T34.21-21-? Page 5
TABLE I
Vapor Concentration of Chlorine Pound Among; the Cell Series In Building 137
Location
p.p.m. (by Volume)
1. Center aisle between series 45 and 46 (10-4-49)
and 1.44 cloudy/raining
2. Center aisle between series 41 and 42 (10-4-49) 3. Center aisle between series 37 and 38 (10-4-49)
0.72 O.31
It It It It
tl II
4. Center aisle between series 33 and 34.(10-4-49)
5. Between series 45 and 47
(10-4-49)
6. Between series 41 and 43
` (10-4-49)
0.31 O.31 2.16
It II
II
11 11
it n
11 11
7. On top series 43 8. Between series 46 and 48
(IO-5-49) (IO-5-49)
1.13 cool and clear 6.80- tl 11 II
9. Between series 42 and 44 10. On top series 46 11. Between series 35 and 37 12. On top series 35 13. Between series 31 and 32
(10-5-49) (IO-5-49) (10-5-49) (IO-5-49) (IO-5-49)
14. Between series 38 and 40
(10-5-49)
15. On top series 36
(IO-5-49)
16. Between series 32 and 34
(IO-5-49)
17. Near compressors
(10-5-49)
18 Center aisle near 13*14,15, 16,17,18 series
19. On top series 39 repairing leak
(10-6-49)
4.00 3.30
If
n
II 11
It
n
1.44 ti 11 1.44 tt it 2.16 tt it 1.13 it if 1.13 ft 11 0.31 tt 11
It
GO
II --H O
fl CO
cn
II
It CO
II
0.31 11 ti
II
O.31 it if
II
and
2.16 cloudy /raining
20. Near two mechanics repairing compressor(lO-4-49) 4.40 " " "
21. On top series 46 (when back pressure
operator added water)
(10-6-49)
22. Between series 15 and 17
(10-6-49)
7.30 0.72
II
II
23* On top series 15 24. Between series lo and 18
25* On top series 16
2o. On top series
repairing leak
(10-6-49) (10-6-49)
(10-6-49) (11-18-49)
ll44 "
0 72 "
"
3.29 cool and clear
CulGJ
^lUUUCUlxwa^ uvjuu*
i^C
fi *
T34.21-21-3 Page 6
TABLE II
Vapor Concentration of Chlorine Pound Among the Chlorine Cell Series in
Building 295
Location
p.p.m. (by Volume)
1. Between series 93 and 95 2. Between series 92 and 94
(11-18-49) (11-18-49)
3- ' Between series 93 and 95 and on top (11-18-49)
4. On top series 103
(11-18-49)
O.38 clear and cool 0.36 " II II 0.72 " (1 II 1.53 " It It
5. On top Beries 104 6. On top series 110
(11-30-49) (11-30-49)
1.13
It 11
0.36 " n II
7. On top series 109
(11-30-49
4.4
K II
8. On top series 103
(11-30-49)
3.6 * " 11 ti
9. On top series 101 (men setting it up)(11-30-49) 14.8, 9*4 11 ll
10. On top series 99
(11-30-49)
11. On top series 98
(11-30-49)
12. Center aisle near series 92, 93, 94, 95 (11-30-49)
11.5 10.8
ti
"u
2.56 " 11
It 11
11
3. In the chlorinating of the cell caustic for bleaching
t]'l900JLS
solution at the cell brine plant no irritating or excessive amounts
of chlorine escaped during the normal operation.
The results of air analyses collected during the preparation
of the bleaching solution are shown in Table III
TABLE III Vapor Concentrations of Chlorine Pound in the Making of Bleach Solution, Building # 303
Location________________________ ________ p.p.m. Chlorine (by Volume)
1. Platform near tank for making bleach solution. In the fumes at the start of bubbling chlorine through the sodium hydroxide
2. In the fumes after one-half hour of bubbling 3. In the fumes after one-hour of bubbling and
finishing batcji up
1.1 1.1
1.1
Biochemical Research Departtner. T34.21-21-5 Page 7
4. The possibility of exposure to chlorine vapors during
the loading of tank cars and cylinders was investigated, sensory
perception usually being employed a3 a measure of exposure. If a
good vacuum was pulled on the tank car and the connecting lines purged,
there was little chance for exposure when removing the valves and
testing the car for moisture. With properly repaired valves and
tight connections, there was no exposure during loading.
5. In the loading of cylinders, an inside Job, there was
more chance for exposure to chlorine. During one visit the delivery
line for the liquid chlorine became plugged. In removing the connect-,
ing linesj insufficient time was allowed for purging and excessive
t
amounts of chlorine were found to exist.'
6. During normal operation of the filling of the cylinders
no excessive amounts of chlorine were found. The results of air
analyses taken during the leading operation of ton cylinders are
collected in Table IV.
Table IV
Vapor Concentrations of Chlorine Pound During the Pilling of Ton Cylinders of Llculd Chlorine. Bldg- 270 (11/15/50)
Location
p.p.m.
1. Breathing zone of operator as he disconnected purge lines from empty ton cylinder
5.12
2. Breathing zone of operator as he disconnects
lines from full ton cylinder of liquid chlorine (line became plugged aid insufficient time was allowed for purging)
8.2
ST006745
_
Biochemical Research Department T34.21-21-3 Page 8 7. In the operation of changing the drying towers in the V cell buildings, high enough concentrations of chlorine and sulfuric acid were encountered to saturate a respirator. Table V shows the concentrations of chlorine found during this operation. SULFURIC ACID (PLUS CHLORINE) I. Significance of Sulfuric Acid Exposure 1. Sulfuric acid fume or mist has an acute irritating action not too different from that of chlorine'. The problem presented by this mixture is practically the same as that presented by chlorine alone. The exposure is short and the concentrations sufficiently low that no great hazard is presented by the operation. It is one that occurs .regularly, however, the one can question whether or not it is really necessary. II. Observation and Presentation of Data 1. The odor of sulfuric acid fumes was masked by the chlorine. Air analyses during the operation showed the presence of considerable acid fumes, however, the exposure was of short duration. 2. The results of the air analyses are collected in Table V and can be compared with the maximum allowable concentration of 0.25 p.p.m. for an eight-hour exposure.
(Table V - page 9)
ST006746
Biochemical Research Department
T34.21-21-3 Page 9
Table V
Concentrations of Chlorine and Sulfuric Acid Fumes Found During the Emptying of a Drying Tower to the
Sewer, Building 157
v
Location
p * p m. clp (by volume)
p.p.m. H2SO4 (by volume)
1. Operators breathing zone as he opens valve to release sul furic acid from tower to sewer (first series of towers)
3*3 (5 min.)
5.7 (5 min.)
2. Area near sewer after the tower wa3 dumped (first series of towers)
5. Operators breathing zone as he opens valve to release sul?furic acid from tower to sewer (second series of towers)
; 1.5
'
13-8 (5 min.)
2.5 5.9 (5 min.)
ST006747
.4. Area near sewer after the tower was dumped (.second series
of towers)
2.9
2.1
ALKALI DUST (PROBABLY SODIUM CARBONATE)
I. Observations ana Presentation of Data
1. No maximum allowable concentration has been established
for alkali, however, based on plant experience, no significant amounts
of sodium hydroxide were found.
2. The presence of finely dispersed titratable alkali was
checked by air analyses among the various cell series and the results
are collected in Table VI.
Table VI
Location
Dust Concentration of Sodium Hydroxide Found
Among the Chlorine Cells Series in Buildings 137 and 2QS
i^ldg. 1^7
~Mgs./cu .meter as HaOH
1. On top of series 47 2. Between series 45 and 47 3. Between series 41 and 43
4. Between srie3 50 and 48
5.. Between series 42 and 44 6. Between series 14 and 16 7. Between series 34 and 36
8. Between series 15 anc 17
(10-6-49) (10-6-49) (10-6-49)
(10-6-49)
(10-6-49) (ll-l8-4g) (11-18-49)
(11-18-49)
same as blank " "
"
'" 2.44 2^44 '
2.18
aiocnemicai nesearcn neper t.T.ent T3* .21-21-3 Page 10
Table VI (cont'd)
--aififr i5--
9. Between 10. Between 11. Between
12. Between
series 92 and 9^ series 95 and 97 series 109 and 111
series 104 and 106
(11-18-49) (11-18-49) (11-18-49)
(11-18-49)
1.95 0.66 0.80
1.14
MERCURY I. Observations and Presentation of Data
1. Air is constantly being evacuated from the mercury
arc rectifiers and discharged into the rectifier room. The pos
sibility of some mercury vapor being given off was checked by
0'i9001S
sampling at the outlets of the vacuum pumps. The results of the
air analyses are collected in Table VII and can be compared with
the maximum allowable concentration of 0.1 mg./cu. meter. These
concentrations of mercury have no significance whatever.
Table VII
Vapor Concentrations of Mercury found in the Rectifier Room, Building 137 (11-13-50)
Location
Cone. Kz. Vaoor (by volume)
1. Directly beneath the outlet of the low pressure vacuum pump for G-2 skid of mercury arc rectifiers
^0.006 ngs./cu. meter
2. Directly beneath the outlet of the low pressure vacuum pump for G-l skid of mercury arc rectifiers
3. Directly beneath the outlet of the low pressure vacuum pump for H-2 skid of mercury arc rectifiers
/0.006 mgs./cu. meter ^0.006 mgs./cu. meter
4. General air sample taken between
skids G-l and H-2. Circulating air shut off for winter conditions
/0.006 mgs./ cu. meter
ST006749
, Biochemical research Department T?4.21-21-3 Page 11
PITCH I. Significance of Pitch Exposure
1. Coal tar pitch from many different sources has produced a variety of effects in the skin: photosensitivity; acne and other dermatosis; pigmentations and growths, some of which are benign, others malignant. It is said that about half of the cancers at tributable to occupational exposures are due to pitch. The heavier fractions1 and t ars of some petroleums and of shale oil have similar actions. One obtains the impression from published information that the rather heavy exposures among pitch workers cause a high incidence of skin injuries.
2. It is apparent that the men handling pitch in the chlorine cells come in direct contact with the material, resulting in prolonged and repeated'contacts upon some portions of the body. The data in Table VTII indicate a moderately dirty atmosphere.
3. The data in Table IX represent counts of small particles, roughly of particle size 0.1 to 5 microns which may be inhaled. This data indicates that relatively small amounts of pitch dust are being Inhaled. Since the literature contains no reference to toxic effects attributable to inhalation, we are not greatly concerned about inhal ation of pitch dust.
Excessive skin contact with pitch dust is to be controlled by arrangement and design of the process to eliminate manual tendllng and dispersion of dust#by personal protection of workmen,and measures to assure a high degree of personal cleanliness. The clothing and bath requirements on these jobs have been indicated. It is recommended that the men working directly with pitch be given medical examinations at regular ity;ervals.
i3iuuaemica.i neseai-u; aacueu'csent
T34.21-21-3 Page 12
II. Observations and Presentation of Data
1. Several exhaust hoods had been installed to control the
dust exposure when grinding pitch. The men working on the pitch
grinding equipment, however, through known experiences, are apparently
exposed to amounts of pitch sufficient to cause photosensitivity.
2. The results of air analyses taken in the worker's breath
ing zone and in the work area during various operations encountered
in pitch-grinding are collected in Table VIII.
Table VIII
Dust Concentrations of Pitch Found During the
Grinding and Handling Operations in Preparation of Making Cell Cement - Building 196
Location
Cone. Ngs./cu. meter
1. Breathing zone of worker as he opens metal drum o pitch tar and breaks up the
contents
63
2. Breathing zone of worker as he shovels broken pieces of pitch into the grinder and dumps buckets of pitch into mills
306
ST006750
3. Breathing zone of worker as he rakes pulverized pitch from the cyclone anc shovels It into the buckets
4. Breathing zone of worker as he sweeps area after grinding and filling buckets"
ca 4=3
5. Breathing zone of worker as he operates the cable hoist to dump bucket of pulverized
pitch into hopper >r the mixer
209,24?
3. The results of cust counts taken in the general area and
during the various pitch grinding operations are shown in Table IX.
(Table IX - page 13)
xiocnemicai rtesearcn Department ' T34.21-21-3
Page 13
Table IX
Dust Concentrations Found During the Various Pitch grinding operations and in the General Area
Location (Breathing zone samples taken whenever possible)
m. p. c. f.
(average of several ________ counts)
I. Shaking out broken pitch from metal drum
5
2. Breaking up lumps 3. Shoveling broken up pitch into grinder'
7
8
4. Dumping buckets of ground pitch to mills 5. Sweeping up area where pitch is ground . 6. Raking out pulverized pitch
5 7 5
7. Filling buckets with pulverized pitch 8. Sweeping area where buckets are filled
5 2
STO067 5 1
9. Dumping bucket to mixer
t
10. Gen. atmosphere near foreman's desk
II. Area in front of small mixer while dumping cement to the small mixer with pitch
5 5
4
12. Area in front of small mixer while dumping the pitch cement mix
4
15* Area in front of small mixer with men working on poured casting
14. Area of building where men are working to prepare the cell forms
GRAPHITE DUST
5 5
I. Significance of Graphite Dust Exposures
1. There are a few reports of lung injury (pneumoconiosis)
among persons working with graphite. Nearly all reports have
dealt with natural graphite containing an appreciable amount of
other minerals so that It is not definite that graphite dust alone
has an adverse effect.
TJ4.21-21-5
Page 14 2. It i3 apparent that considerable amounts of graphite are
dispersed in the air, but the counts of particles susceptible to inhal
ation fail to Indicate any exposures that are questionable. If workmen
were regularly and uniformly exposed to counts of more than 50,000,000
particles per cubic foot, correction would be called for.
II. Observations and Presentation of Data
1. A dusty atmosphere was created when a worker used an
air hose b. remove the loose graphite from the plates before loading.
There was still sufficient loose graphite remaining on the plates to
make the loading of them very dusty.
2. The results of air analyses made during the loading oper
ations are shown in Table X.
Table X
Dust Concentrations of Graphite Pound During the
Loading of Plates into the Buckets in Preparation for Precnatlng with P.F., Bids:. 261
Location
Dust Cone. .`Mg./cu. meter
ST0Q5752
1. Breathing zone of worker blowing loose graphite off a stack cf plates with an air
hose (room closed up for winter conditions)
22o0
2. 5reathing zones of two workers as they load a bucket with graphite plates
2570
5. Several dust counts were taker, curing the place loading
and in the general atmosphere. The results of these councs are shown
in Table XI. These values can be compared with the caxir.uru allowable
concentration of 50 m.p.c.f. for an inert dust.
4. Several dust counts were taken in the machine shop, both
during the operation of the machines and in the general atmosphere
through the area. The results of these counts are shown in Table XI also.
Biochemical Research Deoartment T34.21-21-3 Page 15
Table XI
Dust Concentrations of Graphite Pound During the Loading of Plates and Various Operations in the Machine Shop.
Treating Room
Location (Sample taken in the breathing zone of worker whenever possible) .
m.p.c.f. (average of several
ST006753
1. Blowing the loose graphite off the plates before loading them
2. General atmosphere in the room after blowing
3. Piling the plates into the buckets
4. General atmosphere of the treating room after
finishing the loading of the plates '
10 min.
15 min.
20 min.
30 min.
45 min.
5. General atmosphere in the treating room In the morning when the plates are unloaded
Machine Shop
6. General atmosphere in the machine shop early In the morning before work is started
7. Cutting corners off of boards at band saw
8. Running plates through bevel machine
9. Near new machine for grooving boards
10. Near old machine for grooving boards
11. Placing boards in machines
12. Removing boards from machines
13. Where operator 8lt3 after loading machines
14. Blowing small area from machines so board is locked in
15. Blowing machine off for cleaning
16. Sweeping up area around machines
(Table cont'd on page 16)
50 55 50
20.1 28.3 35.2 30.8 41.0
2.0
7 20
8
10 9
8
9 10
11 10 8
xnocneuicai nese-x-cu ue^arLcen:
T3**.21-21-3 Page 16
Table XI -fcont'd)
17. General atmosphere near foreman's desk
8^
18. General atmosphere near crib
5
19. General atmosphere other end ofshop
5
20. . General atmosphere office area
4
21 Janitor sweeping floor FORMALDEHYDE
5
I. Significance of Formaldehyde Exposures
1. Hone of the exposures measured during normal operation
were excessive. II. Observations and Presentation of Data
1. In the making of the phenol formaldehyde resin, the odor
of formaldehyde was noticed throughout the room, however, only during the blowing 6f the mixing tank was there evidence of eye irritation.
2. In all cases where air analyses were made, the concentration
of formaldehyde found was below the maximum allowable concentration of
5 p.p.u. The results of air analyses are collected in Table XII.
ST00675ii
PHENOL
I. Significance of Phenol Exposures
1. Hone cf the exposures measured curing normal operation
were excessive.
II. Observations and Presentation of Data
1. Very little odor of phenol was noticed during the various
operations of making phenol formaldehyde resin. The results of the
air analyses can be compared with the concentration of 10 p.p.m. phenol
found through past company experience to be an acceptable limit.
2. Table XII also shows the results of air analyses for phenol concentration.
Biochemical Research Departmen TJ4.21-21-2
Page 17
Table XII
Vapor Concentrations of Formaldehyde and Phenol Found During Various Operations of the Phenol Formaldehyde Resin Process, Building 226
Location
(Winter conditions - doors and
windows closed)
_________
p.p.ra.
Formaldehyde (by volume)
p.p.m.
Phenol (by volume
1. General air sample taken in front of reactor and near operator's desk (reactor-up to temp.)
2. From an elevated platform between the reactor and mixing tank (reactor up to temp.)
2. Next to the mixing tank and oper ator's desk
4. Near the mixing tank as phenol was blown in from trailer outside
1.0
1.0 0.44
0.40 O.87
0.69
5. Near the mixing tank as formaldehyde wa3 pumped in from storage tank
6. Near the mixing tank as air was blown to mix concents
7. Near the mixing tank and operator's desk after blowing had stopped
1.27 2.6, 2.6 4.0
1.04
8. Near the vacuum still (operating) in the area where operator spends considerable tine making Insulating plugs
1.5
9. Breathing zone of operator filling 100 gal. drum with evaporated P.F. solution
2.9
10. Breathing zone of operator filling four
50-gal. drums with neutralized and evaporated
P.F. solution for the Texas Division
2.4
11. Operators breathing zone filling six 50 gal. drums of formaldehyde for interplant use. (work done outside on cold, windy day)
.60
1.19 1.11
0.87
ST006755
/
Biochemical Research Department T5^.21-21-5 Page 18
ASBESTOS
I. Observations and Presentation of Data
1. The handling of dry asbestos in making up a slurry of
caustic, water and asbestos does offer an exposure to finely divided
particles of asbestos.
2. The results of dust counts taken in the breathing zone of
a Worker as he weighs, dumps, and stir3 the a3be3tos into the slurry
are shown in Table XIII. These values can be compared with the max
imum allowable concentration of 5 m.p.c.f. for an- eight-hour exposure.
Hone of the exposures measured during normal operation were excessive
since the duration of exposure is short.
Table XIII
Dust .Concentrations Pound During the Handling of Dry Asbestos in the Covering of Cell Diaohraeas
Location (samples taken in worker'sbreathing zone)
m.p.c.f. (average of several
__________________________________
1. Dumping bag of weighed asbestos (48 lbs.) to slurry tank
8
2. Stirring and mixing the as'oestcs with water
10
3. Weighing out a bag of asbestos
5
ST006756
be -8