Document reomXNJzZmRon7R2LGO7wNV8G

RESPONSIVE, OFTEN BY WAY OF ILLUSTRATION, TO THE FOLLOWING INTERROG. NOS., PREVIOUSLY ANSWERED IN JULY 1990: #8, 11, 13, 14, 17, 23, 25, 31, 32, 33, 34, and 35. p r\ r/ .. C r~ y vi 035059 SHOP SAFETY MANUAL RECEIVED SE? 181951 R. B. K.fcNNUY ! iI MAGNOLIA PETRQLHM CCUPANI REFINING DIVISION pVy. rV, r' rO 035060 HOW TO USE THIS MANUAL This manual gives safe working practices for specific 3hops and operations at Beaumont Refinery. It is put in thi3 form so that it can be kept up to date easily. On the next page is a list of all the shops and operations covered. By each name is that shop or operation'3 section number. To find safe practices for the Pipe Shop, for in stance, you first find that its section number is A. Then look for the fourth section in the book. There may be several pages in each sec tion, so a page number is added after each sec tion number. Thus, 4-2 means the second page in the fourth section. Replacements will come to you with the numbers typed on each page. Simply tear out the old pages that have the same numbers and insert the new ones in their place. Additions will have new numbers. Remember that these practices cover only those that apply to special groups. Those that apply to all or most employees are given in the general safety manual "You Bet Your Life." w ^ `-X 0350*! INDEX OF SHOPS AND OPERATIONS Name- Barrel and Grease Plant Boiler Shop Car Shop Carpenter Shop Central Shop Electrical Shop Instrument Shop Laboratory Labor Section Lead Burning Loading Racks Machine Shop Mason Shop Paint Shop Pipe Shop Process Control Laboratories Processing Rigging Section Storehouse Transportation Welding Shop Wharf Sect: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 On tr o rwv 035M2 5 P\J /KVj r ossoea f BARREL AND GREASE PLANT 1. When cars are being moved by car mover, do not hold to car. Use brake. 2. When moving one car of a group, be sure the remaining cars are firmly chocked. 3. Keep at least four feet from car-moving winch. 4. Always remove hook when you have finished moving a car. 5. Never allow any truck, drum, or other ob struction to remain near the railroad tracks. Do not report it - move it. 6. Use caution when opening box car doors. Keep clear of opening as contents may fall out when door is opened. 7. Watch for nails or other obstructions on floors or walls of cars. 8. Drums must be handled with caution when roll ing them, stacking them or moving them in any other way. Don't permit familiarity with drums to deaden your common-sense in avoiding drum accidents. 9. If floor becomes oily or greasy,have it clean ed up immediately with sawdust or commercial absorbent. 10. Do not handle oily drums; clean them first. 11. When filling or dumping drums of inflammable materials such as ketone, naphtha, or gaso line, use plenty of care in handling drums to avoid sparks. Store such materials only in places designated by the supervisor. p r> r ~ .* kJ v <_ A* J 0.15064 BARREL AND GREASE PLANT 1-2 12. In filling drums at the wharf with in flammable materials, make sure loading lines are grounded and fire equipment is in place. 13. Always pull elevator gates completely down. 14. Lift trucks are to be operated only by per sons authorized to do so. Do not fill their gasoline tanks with motors running. Do not lift forks while vehicle is moving. 15. All elevators, conveyors and lifts have de finite operating instructions that must be followed. Know all emergency stops and measures to be taken. 16. Before letting anyone enter kettles or mix ers, switches must be pulled and tagged and the supervisor's approval given. 17. Use rubber gloves and goggles when handling chemicals. 18. Do not climb over or walk on roller convey ors. 19. Do not wear gloves when handling cases on the power conveyors. 20. Keep hands clear while handling pails and drums to feed the air operated lid crimping machines. n. nr.''.' U V/ v w 035065 b o il e r shop (* ' ] rUrW.lr- ' V 035066 BOILER SHOP 1. When using mechanical hoists on heavy mat erials, take precautions to prevent over balance of load. 2. Do not light any rivet heaters, furnaces, or torches outside of an approved job until a Hot Work Permit has been issued to cover that job. 3. Lights carried into tanks, stills, tank cars, around buildings or in areas where gas vapors could be present should be vaporproof. 4. Cut no metal or rivets when men are working in front of you. 5. Be sure that scaffolding is well-built and provided with guard rails if necessary. 6. Get the approval of the operator in charge before beginning work on boilers, super heaters, economizers, or auxiliaries. 7. A rivet heater should keep a bucket of water by his forge at all times so he can quench his fire in case of emergency. 8. In moving scaffold buggies in tanks, use care to prevent foot injuries from wheels or rollers. 9. Never caulk, chip or drill under pressure in a processing area except with the ap proval of authorized processing personnel. 0350? BOILER SHOP 2-2 10. New equipment in service may be caulked tight at pressures and temperatures consid ered safe by the foreman. 11. See that all cables, ropes, chains, and blocks are of such size and condition that they will safely support all loads to be handled. 12. Cutting, punching and drilling on roofs or shells of tanks or other vessels should be done only after a Hot Work Permit has been obtained. 13. Make a thorough inspection of tank roof ring bolts and vent3 before using them to support men or scaffolds. 14. Inspect all stairways, tank tops and lines as you visit tanks. Report major defects. Keep off roofs if possible, particularly roofs showing 3igns of rusting. 15. Don't go on top of tanks during storms. 16. Avoid using mushroomed or defective tfaols. 17. Proper goggles must be worn while heating rivets, riveting, caulking and bucking-up. Other types of work requiring goggles are named in "Play It Safe." < nw r x~j -i. 035M9 P r> r - 035M9 r CAR SHOP 1. Here are correct practices in preparing tank cars for work to be done inside cars: (a) Acid cars - Fill 3/4 full of water and boil with 3team for three hours. Run water out of car, add Sal-Soda to dome to neutralize and then 3team three more hours. (b) Gasoline cars - Steam four hours, cool, clean out rust and steam three hours. (c) Butane cars - Fill with water. (d) Crude or asphalt cars - Steam twice and clean once, alternately. (e) Lube cars - Steam twice and clean once, alternately. (f) Coil cars - Blow out steam coils with air before work. (g) Caustic car3 - Steam and wash. 2. Post a lookout on top of tanks when a weld er is doing work inside of tank. 3. Do not enter any gaseous tank. 4. Leave dome and outlet caps on before pull ing car into shop unless the car is gas-free. 5. Except inside the shop, place the "Men Work ing" 3ign in front of all cars being worked on. Post a lookout for all repair work done in the yard.. 6. Electric welders should, where necessary, use screens while working in the shop. 7. In emptying acid cars with air, never more than 30 pounds per square inch more than that pressure marked on use or the r.'if 035070 CAR SHOP 3-2 car, whichever is lower. Have remote air valve so air can be shut off, when nec essary, without going near the cars. 8. Proper goggles must be worn while heating rivets, riveting, caulking and bucking-up. rU- A tr - 035071 s' V O u o o c/ U3567* SHOP CARPENTER SHOP Scaffolds 1. In planning scaffolds, make 3ure there is a safe way of reaching them. 2. Scaffolds should be big enough for the work ing space. 3. Whenever possible, leave sufficient head-room. 4. Guard exposed edges with standard railings. Where necessary, add toe guards. 5. When erecting scaffolds close to electric wires or equipment - if there is any possi ble danger of contact with them by workmen ask for necessary protection from the Elec trical Shop. 6. When necessary, provide ample protection over doorways and passageways when work is being done on a scaffold above them. 7. Scaffolds cannot be closer than 7 feet 6 inches from the center line of a railroad track or less than 22 feet above them. If closer clearance must be had, get permission from the Carpenter Shop foreman, who will consult with the Switching and Loading Sec tion. Saws 8. Leave all guards in place while sawing; do not leave a saw running. 9. Wear goggles or face shields when using power saws. PO T^- t^r ^- 5673 CARPENTER SHOP 4-2 10. In machine sawing, push small pieces through with a stick. 11. Never reach over a moving saw to get mater ial on the other side. 12. Wien necessary, use guards with circular rip saws . 13* Examine each saw carefully for cracks or other defects before putting it on or taking it off a band-wheel. Use no drilled band-saw blades. All 3aws should be kept sharp. 14. Only experienced men may change saw blades. 15. Placing of wedges between the saw disc and the collar is highly dangerous. Instead, use dado blades. 16. Keep the rip fence parallel to the saw to pre vent kick-backs. 17. Swing saws should not pass the outside edge of the table. 18. Adjust guide rolls on band saws so as to take care of the particular material being cut. Other Practices 19. When wrecking old forms, scaffolds or other wood construction, bend down or remove nails from lumber. Do not leave any loose nails around a finished job. 20. Guard against splinters from slipping boards. c r\rr 035074 CARPENTER SHOP 4-3 21. Only authorized employees of the Carpenter Shop may operate Shop machinery. 22. Do not use shop for storage purposes or pile stock on the tables of machines. 23. ` Unused material should be properly stacked before leaving a job. / 0 035075 ( pKs r'w,' r O *cL/. 035076 CENTRAL SHOP 1. In handling material with power hoists, choose equipment and methods to avoid possi ble accidents. 2. Crane operator must not handle loads over workmen. 3. Only one man on the floor may give signals for a crane operation. 4. Safety face shields shall be worn when oper ating or helping operate friction saw. 5. Only experienced operators, or those under close supervision, shall operate Central Shop machinery. 6. Aisles shall be kept clear and material safe ly stacked. 7. Be constantly alert when operating equipment. Only experienced men should operate steam hammer. 8. When using mechanical hoists on heavy mate rial, take precautions to prevent overbalance of load. 9. When quenching hollow forgings or pipe, do not stand in line with the barrel of the forging or pipe; it might spurt hot water or oil. 10. Clear furnaces of all gases by turning on steam in the furnace before lighting. This will help prevent explosions. iOx jO 035077 CENTRAL SHOP 5-2 11. When lighting a furnace, have the door open. Keep it open until the furnace is hot enough to insure good combustion. 12. When casehardening in liquid baths, take the following precautions: (a) To prevent explosion from splashes of hot liquid, keep the floor around the bath dry. (b) Shield a cold bath before heating. Ihe material in the bottom of the pot often melts before the upper crust is soften ed; the liquid may spurt through the crust, causing serious burns. (c) Be sure all tools or parts are dry and not too cold before putting them in the cold bath. (d) Never eat near the "hardening area" as the bath may contain poisonous material. (e) Avoid breathing the fumes from the hot bath. (f) Be sure your eyes, face and hands are protected with the proper equipment. (g) When charging pots with material, make sure the material is dry. If it has taken up moisture it could explode, throwing hot liquid out of the pot. (h) Add material to the bath at a tempera ture of 1,000 degrees Fahrenheit or less. 13. Use tongs and bars to avoid putting hands under steam hammer. 14. Operator of the steam hammer should set the levers and take his hands off while material is being set in place or taken out from un der the hammer.Ihis is a precaution against his unknowingly putting pressure to levers. nr. r ' 035078 CENTRAL SHOP 5-3 15. When using a steam hammer, guard against ma terial flying out from between the face of the anvil and the hammer or from between the tools used. 16. Before giving the signal to strike a blow, be sure that the work and tools are safe, properly set, and that the hands of the help er are in the clear. 17. Test the die keys and drive them tight. 18. Goggles shall be worn when using the emery wheel and when welding two pieces of equip ment together under the steam hammer, as well as under other conditions as necessary. 19. Mark materials "Hot" when they are to be handled while hot. 20. See that all cables, ropes, chains, and blocks are of such size and condition that they will safely support load to be handled. n. r- 03307$ ELECTRICAL SHOP 035980 ELECTRICAL SHOP 1. Don't take unnecessary risks, even though voltage is low. In handling any "live" circuit, use protective equipment. Avoid even slight shocks vtfien in high places. 2. It's possible to receive a fatal shock from 110-volt circuits under certain con ditions; keep it in mind. Even telephone or signal wires can become crossed with light-tension wires, so becoming dangerout. 3. Stop any person handling electrical equip ment who has no right to do so; report the matter to the foreman. /+. Never handle electric wires while standing or sitting in a wet place. Use care to ob tain insulation from the ground. 5- Never work on equipment in operation ex cept when necessary. Turn power off and, if the control is not within plain sight, be sure that a safety tag has been attach ed to it. 6. Never close a switch without knowing what circuit it controls and why the switch was open. 7. Don't place portable electrical apparatus capable of causing a spark in locations or areas where explosive materials are confined or likely to be present. -8. When working about "live" wires carrying 440 volts or more, rubber gloves must be worn. Wear them as necessary on lower voltages. r\ (^r ` Kj o 035081 ELECTRICAL SHOP 6-2 9. When working on "live" voltages of over 550, two experienced men must be present except in emergency. 10. Place "High Voltage" signs on high voltage equipment. 11. Never bridge fuses by wire or other means. 12. Keep all fuse boxes closed. 13. When working "live" circuits, work on only one wire at a time. Insulate all parts of the body from the ground and other wires of the circuit. Be sure you are protected from falling from scaffolds, ladders, etc., in case of shock. Careless haste is the cause of most accidents on "live" circuits. 14. When working around electrical apparatus, keep sleeves rolled down so as not to expose the arms. 15. Before (1) opening the enclosure or dropping the oil tank of a disconnecting switch start er or other devices that normally carry current, or (2) otherwise exposing currentcarrying parts, make sure the disconnecting switch next back on the line is open and properly locked or tagged out. This is nec essary in all cases. An arc resulting from its neglect could cause a fire or explosion. 16. On enclosures such as metal-clad switchgear, be sure that mechanical and electrical in terlocks are working properly before start ing to remove the circuit breaker. ,--v r-. r ' ' \j h: 035982 ELECTRICAL SHOP 6-3 17. Portable cords should not be tied on metal rods or nails or allowed to come in contact with water or oil. 18. Rules for safe grounding: (a) Grounding should follow fire underwrit ers' rules. (b) The neutral wire of three-wire 110 and 220 volt service should be grounded at the transformer and at all switches. (c) Frames of all electric machines should be grounded. (d) Ground all service switch boxes and conduit systems. (e) Hhen connecting ground wire clamps for portable electrical equipment, work the clamps back and forth at the point of connection. This will scrape rust and paint off and make a good connection. 19. All lighting panels of the three-wire 110 to 220 volt type should have two outside wires fused to the proper capacity while the neutral should be unfused and grounded. 20. In every case wires mu?t be retaped and covers replaced on electrical fittings after repair or trouble shooting. Line Work 21. Linemen should not wear hooks while working on ground, handling heavy materials, or while walking from one job to another. 22. Ifhen piking pole, support pike at shoulder, not at waist. C ELECTRICAL SHOP 6-4 23. When serving linemen, groundmen should not stand at foot of pole but at one side* 24. Linemen should carry a line up pole; it's safer than carrying up wire or other mate rial. Groundmen should not throw materials to linemen. Use the hand line, preferably with a bucket for small tools. 25. Climb the pole, not the fixtures; do not hold to any guys or braces except when nec essary. 26. In opening box-type or other open cutouts, shield the eyes from the flash. In opening cutout3 of any kind, wear rubber gloves. Use a disconnecting pole on high voltage cutouts and fuses. 27. Wear tested gloves and take full advantage of other rubber materials such as line hose, in sulating hoods, rubber blankets, etc. 28. When you "kill" a line by opening a switch, lock the switch open, if possible, or tag it. If in a plant or unit under control of an operator, switch should be tagged with the name of the man ordering, it opened. It shall not be closed except on order of the same man or, on a shift or overtime job, by his recognized relief. 29. Do not let wet hand lines or tackle lines come in contact with high voltage wires. 30. Place pike poles around a shaky pole before removing all wires from it. (O''r-vr_ ELECTRICAL SHOP 6-5 31. When working overhead where there could be danger to men walking underneath, rope off space. 32. When working at heights or standing on hooks or climbers, wear an approved safety belt one you have inspected recently. cA! 035085 (1/o'.Lnr^/fu 035086 INSTRUMENT SHOP 1. Mechanics should -work at all times with plenty of light on the job, especially in precision work or field dismantling. 2. Get the operators approval before cutting out any instrument or opening any line. Then satisfy yourself that it is safe before going ahead. 3. Before disconnecting power from instruments, make sure line is "dead." Power lines should not be worked "hot", if at all possi ble to kill circuits. Tag any open switches or remove fuses to prevent closing of cir cuit. Tape all bare leads and close all conduit openings before putting power back on. U' In removing instruments from the line, bleed off all pressure and liquid possible before disconnecting piping. Tag all instruments going to the shop to show hazardous mate rials instruments may have contained. 5* Never release acids and caustics to open air except at ground level; install temporary drains as needed. A hose of running water should be readily available. 6. Never do any unnecessary lifting or carry ing. Use fixed or portable lifting equip ment and wheeled carrying equipment. Rig up special equipment, if necessary, to avoid heavy lifts. 7. Rotax connections on the Houdry Unit shall be drilled on the air cycle. Replace leak ing valves. Before drilling out pressure connections of any kind, check with operator. 035087 INSTRUMENT SHOP 7-2 8. Keep off furnafte3 of units that are on stream. In cases of extreme emergency, check with your foreman. 9. In dismantling or repairing instruments in the shop, be careful to avoid injury by materials in the instruments as well as mechanical acci dents. Solvents for cleaning should be used outside the shop, in the area provided for that purpose. Avoid inhaling any fumes, or getting solvent on skin. 10. Before welding, brazing or painting,get plenty of ventilation. 11. Wear goggles when using solder pot or solder larger than 1/2" diameter. 12. Never use oil or grease on oxygen or hydrogen equipment or accessories of any kind Use water seal when checking gauges. 13. Do not leave seal hose or line connected to meter that is put in service. 1A. Get approval from Safety Division before us ing soldering iron or electric drill outside of shop. Gagetron Procedure 15. Remove radium capsule and store in lead lined box during unit down periods, when clay hopper . will be opened. 16. Trained instrument shop personnel only to handle this material. -n, tr ; * U Jl. 03598* INSTRUMENT SHOP 7-3 17. In event of transfer or change of radium salts, it must be handled with long handle forceps and exposure limited to as short a time as possible. 18. Spare radium capsule will be stored at Instrument Shop in designated location and properly labeled. 19. Direct contact or excessive exposure to radium can result in serious consequences. Exercise caution in handling thi3 material. A 035989 Vny r>./ ro' vr*/; 035090 LABORATORY 1. Before proceeding vdth any work be sure you thoroughly understand the proper method of procedure and the safety precautions to be observed. -- 2. Always check the equipment for cracks, breaks, and leaks. Defective equipment should be repaired or discarded. 3- Be prepared for contingencies which might arise from failure of apparatus. 4 Cylinders containing gas under pressure, such as oxygen and carbon dioxide, should be properly supported when in use. Extra or empty cylinders should be stored away from heat and danger of upset. 5. Cleanliness and orderliness promote safety. (a) Keep samples, reagents, and equipment in proper storage space. (b) Tffax, grease, and oil should be kept off the floor. Clean spills with Sovasol and clay after extinguishing all open flames in the vicinity. (c) Plainly label all containers, whether holding chemicals or samples. (d) Keep outside of containers clean. Chemicals on the outside of the con tainer may injure the skin. 6. Do not exceed pressure or temperature limits which are set up for the equipment. 7. In setting up glass apparatus, tighten clamps only enough to hold it in place so that breakage will not occur due to heat expansion. nL/ r, r r 035691 r' LABORATORY 8-2 8. When putting glass tubing or thermometers through stoppers or rubber tubing, a lubri cant such as -water or glycerine should be used. A heavy rag should be used to protect the hand from cuts if the glass breaks and the glass should be held as short as possi ble. Fire polish or otherwise smooth sharp edges of glassware and tubing. 9. In submitting glass equipment for repairs, be sure that the apparatus is clean and dry. 10. Assume that all dyed gasolines contain lead and avoid unnecessary contact with the 3kin 11. All volatile toxic materials should be handled either under a hood or in the open air. 12. Keep vapors in the Laboratory at a minimum by: (a) Use of the hood; (b) Proper ventilation; (c) Keep chemicals and samples stoppered; (d) Using caution in opening sample bombs in the Laboratory; (e) Minimum use of wash gasoline. 13* Do not make or break electrical connec tions where inflammable vapors are present. 14. Cool hot equipment, such as flash cups, melting point pans, etc., before washing with naphtha. 15. Do not vent gas bombs or high vapor press ure bombs in room or out of windows. Use equipment provided for emptying bombs. n r> r-r-ly ty 035692 LABORATORY 8-3 16. Remove leaking bombs from building at once. 17. Purge bombs with air before repairing nipples or valves. 18. Engine Maintenance (a) Shut engines down before wiping dust or oil from any part. (b) Stay at a safe distance from running belts and pulleys at all times. (c) Open all electrical source switches before doing any maintenance work. (d) Use box wrenches when possible. KJ 035093 MWatvom-.^ i c' n r^ \rj ' , 035094 LABOR SECTION 1. Hear rubber boots when tank cleaning. 2. If you have handled Houdry salts or lime, take a bath immediately afterward. Change clothes and rinse then out, then return to work. 3. In case of emergency, major fire or disas ter, report to your immediate supervisor. 4. Before cutting into colored concrete, get approval from the Safety Division. 5= Before working in a ditch more than three feet deep, get it shored. 6. Rope off all excavations and put up "OPEN HOLE" signs. 7. Don't wipe or clean any machines in motion. Don't clean switch-rooms in units except when the unit is down or except under the supervision of electricians. 8. Before cutting into masonry around motordriven machines or equipment,find out the location of underground power lines and be careful not to cut- them. 9. When concrete rods are exposed during cutt ing, put either hose or other covering over them, or remove them entirely. 10. When changing tools and when connecting or disconnecting tools and air hose be sure the air hose is turned off and the air pressure in the hose is released before breaking the connection. Do not kink the hose to make connections. cc 035095 LABOR SECTION 9-2 11- Proper goggles must be worn at work requir ing use of a pick or mattock and on other types of work named in "Play It Safe." r\ r- O 0350M I I / \ '( Jt I LEAD BURNING p r -e r. 03509? LEAP BURNING 1. In a closed-in place vhere there is danger of a burner breathing lead fumes, an ap proved-type respirator should be -worn. 2. Wear gloves when handling lead. 3. Woolen clothing offers better protection from acid than cotton - a fact that might be taken into account when lining out your work clothing. 4. Hot Work Permits should be obtained from the Safety Division for work involving flame. These should be endorsed and carried by the lead burner doing the work. 5. When working in acid concentrators, a Work Permit should be obtained from the Safety Division stating that the vessel is safe to work in. r* - L/ V_ 0359S9 035099 f LOADING racks 1. Before loading or unloading tank cars at racks, "Stop-Tank Car Connected" or "StopMen At Work" signs should be placed on track one car length from rack. If track i3 open at both ends, two signs are nec essary, one at each end. 2. Bonding cables and static lines must be connected to tank cars before loading .in flammable products. 3. Tank cars shall not be entered until a Work Permit has been issued. 4. Use only non-sparking tools on Loading Rack No. 5 where propane and butane are loaded. 5* Fasten safety chains on spout before load ing inflammables. 6. Loading or unloading of tank cars shall be stopped during electrical storms. On gaso line cars, close manholes and put outlet caps on discharge chambers. 7. Replace dome covers and bottom cap before moving any car. 8. Do not let tank cars stand with connections on after loading has been finished. 9. Spills in the loading rack areas should be cleaned by flushing with water or by the use of fuller's earth. 10. When men are cleaning inside cars,a stand by should be posted at the manhole opening to assist him. r\ tt ~ ' * O -w" o *_/ 0351M LOADING RACKS 11-2 11. When cleaning lube oil tank cars, one man should be on rack to check with cleaner in car at short intervals. When necessary for cleaner to change to another car he should notify the man on rack that change is to be made so that rack man will know at all times exact location and conditions under which cleaner is working. 12. Never jump from loading rack to tank or from car to car. 13* Do not leave tools on top of tank cars; they are a falling hazard. 14. Sample bottles should be carried in a case to prevent breakage. 15. Avoid striking manhole cover against dome and making a spark. 16. If tank cars are not spotted properly for safe loading, supervisor of rack shall be notified before any loading is started. 17. Hold cars with the hand brake, and,if on a grade or incline where there is a possible chance for the car to roll, the wheels should be blocked. 18. Car inspectors shall check stenciling on all cars to see if tank and safety valves are due for test. If they are, notify Car Shop. f` f'. v \J >-- ~~J 035101 r I t I i /> r\ r~ ^ ^o 035102 MACHINE SHOP 1. Only authorized personnel may handle shop machinery. 2. Keep hands and fingers in the clear when operating machinery. 3. Use a brush for removing chips. Do not use fingers. Do not use compressed air except where absolutely necessary. A. Never use rags close to moving machinery because of the danger of catching them in revolving or moving parts. 5. Wear proper clothing. Rings or loose cloth ing are dangerous while operating or work ing around machinery. Loose shoe laces, ragged sleeves or rolled up pants are equally dangerous. 6. In machining material, make certain it is properly secured so that it does not slip. Don't drill or machine light gauge material on drill press except with clamps or when it is held so as not to cause injury should it slip. 7. Inspect all abrasive wheels for cracks or defects before placing on spindles. 8. Do not use emery wheels out of round. On portable grinders and similar tools, make sure wheels are equipped with guards when ever possible. 9. Keep tool rest close to the face of abra sive wheels and above center .' whenever possible. > !" 035103 MACHINE SHOP 12-2 10, Do not attempt to operate a machine until you have acquainted yourself with operating switches. 11. Do not use file without a handle, and use it left-handed when filing work in the lathe, 12, Take the following steps when necessary to work on equipment where there is a possi bility of gas being present in high concen tration: (a) Obtain permission from operator re sponsible for the equipment before starting work. (b) Have proper safety equipment on hand. (c) The process and mechanical foreman should personally supervise the work when it is known that a definite hazard exists. 13. In making chemical pump repairs, obtain permission from operator in charge and make sure lines are properly drained and blinded. Near necessary protective equip ment, goggles, rubber gloves, etc. Ik. Stand at the side of hydraulic press when pressing off tapers. 15. When starting steam turbines, stand at the outer end of the turbine axis if possible. 16. Before working on steam-driven machinery, the machinist should see that the process operator or engineer has closed the inlet steam block valve and the steam exhaust block valves, and opened the steam cylinder drain valves. r* n MACHINE SHOP 12-3 17. On motor-driven machinery, the service switch should be locked open and a suitable tag placed on the switch to 3ee that the starting equipment is at the "off" position. 18. When work i3 done on compressor cylinder, block the flywheel or crank shaft to keep the weight of counterbalance from moving the cross head. 19. Before removing covers on compressor cylin der valves, pump valve cover plates, or pump heads, slack all cover hold-down nuts and break gasket seals to release pressure. 20. When work is to be done on any machine which has been in gas(hydrocarbon, ammonia, etc.) or light oil service, take care to keep from placing the face directly over the open parts; there may be a possibility of pocketed gases. 21. If valve repairs are necessary, valve bonnets and valves should be removed from the machine and repaired. At no time shall anyone place his hands through valve ports into the cylinder. 22. Keep aisles clear and clean in shop and material off the floor. 23. Always file off burrs left on tin after cutting. 24. Keep air hoists in good condition. Never use defective cables. Take care that cables are wound on drum in proper manner and that they do not become kinked. t") * .  ' I i S .'M (\ n- r* b v O t. 0.15106 HASON SHOP 1. Do not work under any other workmen without solid covering on or over your head. 2. When necessary to cut out brick work or con crete in any processing or gaseous area, get permission from the Safety Division. Take every care to prevent striking a spark. If it 3eems necessary, use a stream of water on the end of the chisel, or use non-sparking hammers and non-sparking chisels. 3. Before tearing down walls or columns, see that all needed shoring is in place. 4. Cutting brick or concrete with an air hammer at a high level should be done from scaffold or platform ladder only. Use a ladder or step-ladder only Then another man is present to hold it. 5. Since scaffolds used by masons must hold up heavy loads, make sure yours is substan tially built and has hand rails and toeboards if they are necessary. 6. See that all scaffold horses are well made from good material, strongly braced and resting on firm foundation - not on piles of brick or tile. 7. See that material is piled on scaffolds so that it cannot easily be knocked over. 8. When cleaning up after work is finished, rope off area where material will be dropped or thrown. .* V./ *r\^,\ p~-. ?-m J i 035197 MASON SHOP 13-2 9. If assigned to work in a hot flue, never take a water ho3e into the flue and release water* Vapor3 coming off hot soot can cause serious burns. 10. Wear goggles when using brick saw and when chipping bricks, tile or cement - at other times, *hen necessary. 11. Always lower swinging scaffolds to the ground yfricn they are not in use. 12. Chains or wire line rather than fall ropes should be used over sharp corners. /"\ 035f03 PAIWT SHOP * I I #35109 PAINT SHOP / 1 Guard against poisoning from paint ingredients. Use gloves if you have an open wound or sore, even though it ha3 been bandaged. 2. When putting "up a swinging scaffold, test it by raising the platform one foot from the ground. Always inspect the tie-off rope and tie-off ring on top of the tank. 3. Swinging scaffolds must be lowered to the ground when not in use. 4. Beware of "live" wires. Don't paint on switchboards or near electrical equipment until it is approved by the Electrical Shop. 5* Do not paint hot surfaces, except with an approved type of paint and upon instruc tions from your supervisor. 6. Spray painters shall equip themselves with approved type respirators vhen spray paint ing. Proper goggles must be worn while scraping and painting. 7. Scraping should not be carried out on any tank while pumping in or out. 8. A safety permit will be secured for all tank scraping and other preparatory work and for tank painting unless the Paint Shop foreman authorizes going ahead without it. 9. Inspect ropes, hooks and blocks before putting them into service. f*> r\ t./ U J 'w/ 035110 PAINT SHOP 14-2 10. Never leave oil or paint-soaked rags in pockets of overalls or wadded up. Place all such rags in covered metal cans. pnr^ ly V. 1. j "-I-' U35JI1 ? i i 035112 CO PIPE SHOP 1. Men should not stand on hand rails, small lines or instrument line racks to reach elevated work unless it's necessary. Get scaffolds or necessary staging. 2. See that blocks have enough capacity to handle the load and that blpcks and chain are in good condition. 3. Ifhen hoisting material or working around electric wires or equipment, call an elec trician. He will advise on and place nec essary protection around wires and equip ment. 4. In lifting, lowering and carrying pipe, one man alone will give the signals. Keep in time with the others. Accidents happen when one man lifts or lowers a load before the others are ready. Broken toes have re sulted from pipe falling due to the use of boards or other makeshifts. 5. Keep feet and hand3 from underneath pipe when it is lowered. 6. INhen stabbing, keep hands out of pipe and make sure threads are caught before letting go. In supporting pipe for make-up, keep hands clear of threads. All pipe too heavy to handle by hand should be securely block ed up. 7. Use good tong3. See that the key i3 sharp and the rivet tight. Tongs with defective keyways should be turned in for repairs. >"K r\ r- . > KJ '-J j 035113 if PIPE SHOP 15-2 8. Make sure tongs are properly adjusted to pipe before starting the stroke. A small board pump block placed near the butts of tong handles and parallel to pipe will pre vent broken toes and mashed fingers if tongs are dropped or 3lip. 9. Line up holes in flanges with spuds or drift pins. Keep fingers out of flange holes. 10. Use a wire brush to clean pipe threads. 11. In holding a drive wrench, stand clear of the man using the sledge hammer. Hold the drive wrench tightly, not loosely, hold the wrench at its top, pressing it down hard against the bolt. 12. Hold flange spreaders while driving. Fly ing spreaders are highly dangerous. 13. Do not remove blinds or break lines until operator in charge has inspected lines and apDroved the work. Try bleeder yourself where possible. 14. In all cases, the process foreman or some one appointed by him must be present when a line is opened. 15. An underground line whose service is not known shall not be opened until a process representative and a mechanical supervisor have approved. 16. Water lines shall not be connected to pressure vessels unless there is a check valve. r\ jr f < \j ; . 0351(4 PIPE SHOP 15-3 17. Use special care when opening hot lines or chemical lines. 18. In repairing caustic or acid lines, pumps, etc., make sure that equipment has been blown out and drained. Goggles, rubber gloves, rubber aprons or suits, and, where necessary, rubber boots should be worn. 19. The man doing the upbolting shall keep him self in the clear in case the line may not be entirely empty. 20. After work is finished on acid or alkali lines, place all hoods back in position over the valves, cocks, flanges, or pumps before leaving the job. 21. Whenever it is necessary to steam out any pipe line or equipment that may be plugged such a3 an asphalt or wax line - the open ends should be amply protected to eliminate any chance of a man being burned when the contents are melted out. If there is an "L" or swing on the open end, the line should be secured; backlash of steam in the pipe can cause dangerous movement. Insulating 22. Goggles must be worn while removing, cutting or lacing up insulation, and during the handling of granulated insulation and all close inspection work. Other types of work in which goggles are necessary are named in "Play It Safe." 23. Do not stand on handrails or stand or walk on elevated pipe lines. r\ r\ p o* u t. 035115 PIPE SHOP 15-4 24. Bend all wire lacing and reinforcement to prevent scratches, tearing clothing, or in jury from exposed ends. 25. When working on hot Rifles or equipment take precautions against burns caused by acci dentally touching*hot surfaces. 26. Be sure all bolts are in place and tight and all test holes welded before covering any equipment. 27. Avoid tying or pulling wires overhead that might make tools slip and so injure face and hands. 28. Use care \rfien working over condenser boxes filled with hot water. Get lumber for prop er footing in all such cases. 29. Exercise extreme caution vhen working near electric wires or electrical equipment. Get electricians to cover lines that are dangerously close. 30. Rock wool, glass wool, or mineral wool in sulation should not be handled without the following precautions: (a) Wear face shield or goggles, respira tor and gloves. (b) Arms should not be extended too far into places vhere insulation is thick. (c) When some of these materials get in eye3, report to the medical staff. (d) If possible, start job on the windy side and work around, with the wind. p rv -- O' v. >-- O' 035!t PIPE SHOP 15-5 Tube Cleaning 31. Do not remove the first plug in a still un til the foreoan has checked to 3ee that the still is properly blinded. 32. The foreman and operator should be present when the first plug is pulled. 33. In mechanical cleaning, insert tube-clean ing motors in the tube end before starting, and do not withdraw from the tube until stopped. 34- In decoking, it is vital that the furnace be completely isolated from the rest of the unit through proper blinding or disconnect ing of lines and use of.vents. This must be checked thoroughly, 35. In decoking, the exhaust line from the fur nace must be located a safe distance from the unit since carbon monoxide and sulfur dioxide fumes sometimes produced can be highly dangerous. / I/ / \ I? p, r~ r' t./ \j _ U35)t8 PROCESS CONTROL LABORATORIES General lo In addition to the instructions below the Process Control Laboratories* personnel should be familiar with safety regulations pertaining to the Laboratory and other re finery divisions when doing some specific work not covered by the practices below. 2. All samples and materials must be clearly ' labeled, initialed by the person to whom they belong and securely stoppered. Con tainers without labels or initials will be discarded. 3. Materials and equipment not in use must be returned to storage to avoid delay in lo cating then when need arises and to insure maximum working space in the laboratory. 4. Spillage should be removed immediately. Cleaning should be done with Sovasol or water depending on the type of materials involved. 5. Cylinders containing compressed gases and other equipment liable to fall and cause injury must be supported from stationary objects. 6. Keep inflammable materials at a safe dis tance from flames and remove them from the laboratory as soon as the work is completed. Volatile materials such as light gasoline fractions must be kept in cold storage and not close to electric equipment which is not explosion proof. V./ V, 035119 PROCESS CONTROL LABORATORIES 16-2 7. Do not clean hot equipment with volatile solvents. So Do not pour materials which easily solidify in laboratory sinks. Acid can be disposed of in this manner only if diluted with very large volumes of water. 9. Keep the laboratory atmosphere free of fumes by proper ventilation and by using hoods as much a3 possible. 10o Never exceed pressure and temperature limits for which equipment is designed. 11. All leaded (dyed) gasolines must be handled by observing precautions outlined in Motor Laboratory instructions. 12. Oily rags must be placed in waste cans pro vided with covers. 13. Do not use rubber in contact with oil. In exceptional cases synthetic rubber (Neo prene) might be employed but connections must be as short as possible. Oil swells and dissolves rubber (and sulfur) weakening joints. 14. In diluting sulfuric acid with water, al ways add acid to the water and preferably use crushed ice in place of water. 15* Use face shield and protective clothing in handling, strong acids, alkalies, glacial acetic acid and other hazardous chemicals. f\ PROCESS CONTROL LABORATORIES 16-3 16. Persona working in cold rooms must wear clothing provided for that purpose and noti fy some other person who i3 under obligation to inspect every 15 minutes. 17. Persons entering hot room must leave the door open while within. 18. Use red tags for identification of all haz ardous chemicals. 19. First aid cabinet may be used only when Medical Department is closed. Always report after the cabinet has been opened. 20. Do not pour any petroleum products in the laboratory sinks. Special "slop oil" drums are provided for this purpose. Solids must be put in the "skips" outside the laboratory. 21. A fresh air mask must be worn when working with fuming sulfuric acid, sulfur dioxide, or sulfur trioxide. 22. No one is permitted to work in the cold rooms when he is the only person present in the Process Control Laboratories. Starting New Investigations 23. Every person should understand the problem on which he is working and must be familiar with the steps and precautions that might need to be taken in handling dangerous sub stances. Equipment should be inspected for leaks and provisions made for meeting possi ble emergencies. PROCESS CONTROL LABORATORIES 16-4 24. In setting up glass and other fragile equip ment avoid excessive tightening of clamps to prevent breakage caused by heat expan sion. In cutting glass tubing, make one mark with the file and break the tubing by protecting hands with rags, placing the file mark opposite the thumbs and' pulling the tubing outward and backward. Smooth the sharp ends of the broken tubing by holding them over a hot flame. 25 Glass equipment sent for repairs must be clean and dry. 26. Apply as little pressure as possible in forcing glass tubing or thermometers. Mois ten the glass tubing with water or glycer ine when connecting it with rubber to pro vide lubrication. Carefully push tubing through the stopper until enough of it appears on the other end to start pulling. Always protect hands with rags. Distillation 27. With glass equipment use shields and tray3 which may be filled with sand, to avoid in jury in case of breakage. c r*. r~ , 352* i l( / nrrr c U -V. V. O 'J 035t23 PROCESSING 1. Operators and pumpers must give their ap proval before their equipment is released for maintenance -work. 2. Open valves on pressure gauges just enough to let needle register. 3. Stop leaks as soon as they are discovered. In cases where this cannot be done at once, a steam jet should be played on the leak until repairs can be made. 4. Keep oil spills washed up with water. 5. Operators and pumpers finding a large spill of inflammable liquid or gas in quantity should notify maintenance personnel in that area and ask that they stop work until the condition has cleared. 6. The operator or pumper responsible for draw ing of water from tanks and vessels, draw ing of samples, or venting of pumps should stand by until all valves are closed. 7. Operators will not approve connecting water lines to pressure vessels or oil lines un less there is a check valve. 8. Steam out fireboxes thoroughly before light ing gas burners. 9. Do not vent gas or light gasoline vapors to atmosphere without permission from the supervisor. n n- r~ c~ r < V./ o D , PROCESSING 17-2 ) \ 10. When repairs are being made to leaking 1 lines or fitting on units in operation, a member of the Process Division should stand by until repairs are completed. 11. Do not draw oil into the sewer or on the ground from any vessel or line unless there is no other way to pump out or empty. 12. Do not have blinds removed or lines broken until lines have been inspected and approv ed. Try bleeder yourself where possible. 13. If, in an emergency, anyone enters a vessel or tank where lines have not been blinded, inlet and outlet valves should be protected by locking in position or by a guard. u. Operator should check to see.that the still is empty and blinded before removing the first plug from any oil tube. 15. Blind gas lines on furnaces as soon as fires are cut out. Steam furnace before removing blind on gas line and be ready to light fires as soon as blind is removed. 16. Use insulated stools or mats, where they are provided, in starting electrically driven pumps. 17. Gas compressors must be blinded off before any repairs may be made on compressor end of equipment. 18. Before blowing any agitator, the treater should notify any men repairing other agi tators close by. p nr n .s- V.' V_^ 035125 PROCESSING 17-3 19. Before opening hatches for gauging, thiefing or sampling, stand to windward so that fumes will be blown away from you. 20. Nitric and other acids should be handled with rubber protective clothing and other goggles. 21. Processing men will not go on top of tanks during electrical storms. 22. Inspect all stairways, tank tops and lines constantly for defects, and report any found. Keep off defective tank tops. 23 No one i3 to enter any vessel that has held oil or gases until that vessel has been properly steamed, vented and blinded and until a gas analysis shows it is safe for entry. 24. Operators must have steam hoses for fire protection at units in place at all times. 25. Men sampling or gauging sour crude or dis tillate tanks and any others displaying the "Poison Gas" sign must wear gas masks. A standby with a gas mask must be in the immediate vicinity. 26. Nhen tanks are changed from sweet to sour service or vice versa. Process Division men must notify Safety Division so danger signs can be changed. 2?. Pump out or displace out with water all . lines and vessels before opening for re pairs unless the general foreman approves otherwise. finr V./ r O r V-' 035128 PROCESSING 17-4 28. Before putting steam or hot oil through the tubes of any condenser, exchanger, or re boiler, make sure 3hell side i3"properly vented. 29. Operators vd.ll not close or permit to be closed any tagged electrical switch with out the approval of the electricians whose name is on the tag, or, in case of a shift or overtime job, by his authorized relief. 30. When starting steam turbines, stand at the outer end of the turbine axis if possible. 31. Operators should be familiar with the loca tion of main 3team valves and power switches, so that if a gasket is blown and is danger ous to approach the pump, it can be 3hut down. Use care, though, to choose valves that do not shut down vital operating equip ment. 32. Make sure that pump bleeders are closed and discharge lines are open before starting pump handling chemicals. 33. Do not gauge acid or caustic tanks vhen tank cars of these materials are being unloadedinto the tank. 34. Tag and identify fittings in chemical ser vice 3ent to the shops so proper precau tions can be taken. Handling of Houdry Salt 35 Extreme care must be exercised at all times in the handling of the molten salt. r- r r- 035127 PROCESSING 17-5 36. The principal hazards involved in handling the salt are as follows: (a) Personalinjury, due. to bodily contact with the moltensalt. (b) Poisonous effects and asphyxiation re sulting from nitrogenperoxide ga3 evolved during burning of any organic matter such as wood, rags, or oil in contact with the salt. (c) Fire hazards due to contact of molten salt with organic matter. 37. Goggles shall be worn vhenever handling salt in a loose or crystalline form. 38. Asbestos or fireproof gloves must be worn in all cases when it is necessary to handle any equipment containing or covered with molten salt. 39. In any case where cold salt, either in loose or solid form, contacts the skin, wash the affected parts immediately with water. 40. If molten 3alt should contact the skin or clothing, wash the affected parts with large quantities of water. Remove any salt satu rated clothing immediately and wash it with water. 41. In case salt gets into the eyes, submerge the face in water (water tub or in stream from drinking fountain) and blink the eyes rapidly. 42. The presence of nitrogen peroxide gas may be detected by a rather sweet odor or by a LIGHT YELLOW OR ORANGE COLOR OF FUMES YJHEN p r\ r V.. V. V, 035J2 f PROCESSING 17-6 IN LOW CONCENTRATIONS AND PROGRESSING TO A REDDISH BROWN WHEN IN HIGH CONCENTRATIONS. 43. Fumes evolved from the burning of any or ganic material in contact with the salt may contain nitrogen peroxide gas in concentra tions sufficient to cause asphyxiation if inhaled. 44. Leakage of oil into the salt system in the catalyst cases vri.ll produce nitrogen pero xide which will appear in the exhaust from the salt system evacuation ejector. Any evidence of such fumes should be reported to the Plant Foreman at once. 45. The salt is a very rapid oxidizing agent, hence any organic materials may be ignited immediately upon contact with it and rags or clothing may spontaneously ignite if they are rolled or wadded up in a tight bundle after having been contacted with the salt, either in molten or crystalline form. Keep any such material separate and see that the salt i3 thoroughly washed off before disposal. 46. Use all precautions possible to prevent the molten salt from contacting any organic ma terials . 47. Never use rags for wiping any equipment which has been in 3alt service, but wash the equipment thoroughly with water. 48. Wash all salt spills immediately with water. p nr r>V 035189 PROCESSING 17-7 49. Icicles of salt should not be allowed to hang from the case structure. They should be broken off frequently to prevent their falling and causing any injury upon strik ing a person. 50. All pieces of salt should be placed in a separate container located in the case area. No other refuse, 3uch as oily, rags, should be placed in this container. P r> r p v.* w 03513# \ p r\ r* r ^ 035131 f RIGGING SECTION 1. All equipment - and especially guy lines and load lines - should be checked by the rigger on the job before operations start. 2. Keep a look-out available to warn employees from walking under suspended loads. Rope off working areas when near processing equipment. 3. When riggers call for transportation equip ment, operators of that equipment will take signals from the rigger in charge. 4. Rope should be protected with pads or blocks when taken around sharp edges. 5. Hand lines must be fastened to the load it self so its movements can be fully con trolled. 6. Rope guy lines and gin poles should be left in 3afe condition vhen leaving the job. 7. Gin poles should be equipped with cables instead of ropes where fires are likely to occur or where they are exposed to acid spills or fumes. 8. Rope that has been contaminated by acid or alkali or has been highly heated should be tagged before it is returned to the rigging loft. 9. When using rope for snubbing lines, do not snub against sharp edges or points. 10. Do not use chains on loads. n r~ r ; l. J _ 035132 RIGGING SECTION 18-2 11. flhen using chain blocks, check their capac ity before lifting loads. Do not overload. 12. When using jacks, keep your head away from the lever. 13. Never fasten snatch blocks to a live line, or let loads rest on a live line, or put any stress on equipment in operation. If in doubt, check with the operator. 14. Air hoist operators must avoid putting hands on cable feeding to drum. Use a stick or have someone stand in front to guide the cable if cable piles up. 15. Be sure that air tuggers and snatch blocks are fully lubricated before using them on the job. Never run a dry cable on an air hoist. 16. Check permanent rigging equipment on units carefully. Lubricate cables to avoid abra sion before operating equipment. 17. Check with the Electrical Shop before plac ing guy lines over hot wires. 18. Only one man will give signals on a jobthe rigger in charge. Don't relay signals unle33 it's necessary. 19. Make a thorough inspection of tank roof ring bolts and vents before using them to support men or equipment. Or 035133 1i ( CCCC'.' 035134 STOREHOUSE 1. Only authorized personnel are permitted to operate lift trucks. 2. Due to the storage of chemicals in the east section of the Storehouse, special atten tion to the problems of fighting fires in that area is necessary. Fires in thi3 por tion should be regarded as potentially haz ardous because (1) fumes from some of the chemicals, -when burned, are highly irritat ing and toxic, and (2) there are chemicals present which - when mixed under certain conditions - could produce an explosive fire. Fires in the chemical warehouse should be put out as quickly as possible. If a hand extinguisher is not enough, use a fog nozzle with a fine spray. Here is the procedure to follow; (1) Enter south door No. 1. Gas masks are located close to the material counter. (2) Enter chemical warehouse through the 10' door in the fireproof wall divid ing the tvo storerooms. (3) Switchboard for lights is at the south west door (inside) of the chemical warehouse. (4) Fog nozzles with 150' of l|" hose are located at each of the two east doors (outside on platform). (5) All outside doors and windows of chem ical storeroom should be kept closed except that the south doors may be partly opened when fumes are slowing down fire fighting. STOREHOUSE 19-2 (6) Inflammable gasoline inhibitors are located in the center section of the east aisle* Watch these closely* Move them out the south end of the building if it seem3 necessary. (7) The northwest corner of the chemical storeroom contains Houdry Sovac salts surrounded by inert material. Keep away from this section as much as possible in a bad fire. (8) A fine spray with fog nozzle is re commended for all chemicals. 3. Good housekeeping is essential in all sec tions of the Storehouse. Packaging mate rials must not be allowed to cause unnec essary clutter. c n. r : 035136 I I r / TRANSPORTATION SECTION Shop Safety 1. Plat-based stationary jacks should be used on all repairs Wien the car must be hoisted. Don't use wood blocks or other substitute material. 2. Use the special equipment provided for hoisting equipment from vehicles. .'Don't use knotted chains or ropes. 3. When motors are being lowered into vehicles, no one should be under the engine section. 4. In raising a car by means of a hydraulic jack, have no one under the car. 5. Do no welding on gas tanks with the tank in place. Remove it. Be sure fuel pump and carburetor are drained before removal. 6. Necessary protective equipment must be worn when welding or burning. 7. Carbon monoxide is deadly. Make sure work ing area is well ventilated in the cold months. 8. Motors should be cut off before making re pairs except when necessary to locate or fix trouble. Cut engines vhen greasing. 9. In cranking vehicles, retard spark and make sure gears are in neutral and emergency brake is on. Use the safety grip. Pull up on the crank. r \' TRANSPORTATION SECTION 20-2 10. Before changing tires, always let all air out. When inflating a tire on a split-rim, don't stand directly in frontj hold' the hose with one hand with the body being pro- tected by the truck or car. 11. Before putting gasoline in vehicles, be sure motor is shut off, When filling storage tank for service stand, the filling must be supervised by shop or section foreman, 12. Don't use gasoline or naphtha for cleaning. 13. Oil or grease spills should be cleaned up at once because of danger from drivers stepping out and slipping on it. 14. See that trailer is properly blocked before coupling and uncoupling with vehicle. The driver should supervise. Yard Operations 15. When loading heavy equipment, turn motor off, 3et the hand brake and put the gear in re verse. 16. Drivers 'will not permit any riders on tail gate trucks. 17. When operator leaves bull-dozer, he should lower the blade to the ground. 18. When working with lines on cranes, see thattension is off the boom at all times. Be fore doing any excavating, check with either the engineer in charge or .the job's super visor on the location of underground lines. -v r-.; U35939 TRANSPORTATION SECTION 20-3 19. All blocks should be laid flat when chang ing lines or blocks. 20. When operating equipment near electric lines, operate boom no closer than 10 feetexcept with permission of the Transportation Section's foreman. 21. Equipment for tying down draglines and bull dozers on low-boy should be inspected by the operator after each use. Such equipment should be used only for this purpose. 22. Traveling blocks, slings and all other equipment used on cranes should be checked by the operator at least once every 30 days. 23. Signals to lifting equipment operators shall be given by the hooker except when equipment is ordered by the Rigging Section, in which case the rigger in charge will give signals. Traffic Regulations 24. Yard speed limit is 15 miles per hour, ex cept vhere otherwise designated. 25. Drive slowly when passing units that are down for repairs, at all intersections, and during shift hours when pedestrian and ve hicular traffic are heavy. 26. All traffic signs and signals must be ob served. 27. Sound horn at blind corners and when pass ing pedestrians, bicycle riders and auto motive vehicles. pi r- "p TRANSPORTATION SECTION 20-4 28. Keep safe distances behind vehicles, at least two-car lengths. 29. Do not drive with defective equipment! lights, brakes, steering apparatus and horn must be in good condition. Report for re pairs immediately any defective equipment. 30. Guard against hauling overhanging material on truck beds. When in doubt, check with supervisor so that material can be rear ranged or flagman used while hauling over hanging material. 31. Do not park or stop on roads if vehicle in terferes with traffic. Whenever possible, park in designated areas. 32. Do not enter restricted limits of units if in operation unless permission is granted from operator. 33. Do not remove road blocks or detour signs. 34. Stop before crossing railroad tracks where locomotive cannot be observed at safe dis tances. 35> All persons must be seated viiile riding in trucks. Feet and legs must not hang over truck side or back ledge. 36. Maximum number of passengers will be spec ified on each truck. Do not overload. 37. Only one person besides driver will be al lowed in cab of truck. TRANSPORTATION SECTION 20-5 38. Drivers are responsible for designated num ber of men to ride on each class of truck. 39. Truck driver helper will ride on rear of truck and notify driver of excess riders or any infringement of rules. 40. Temporary seats are to be removed from trucks while delivering material. 41. Do not pass trucks that are taking on or discharging passengers. 42. Each driver must be familiar with all post ed rules and regulations covering traffic in refinery. 43. Report immediately any infractions of rules to Safety Division and Transportation Sec tion. 44. All employees should assist in the enforce ment of the rules and regulations laid down for traffic inside the Beaumont Refinery. 45 Be safe, exercise caution at all times. Distraction while driving may cause an acci dent. X -( n r\ n r,. lj v, t, Vj <>35143 r WELDING SHOP 1. Burners and welders shall wear goggles3 helmets or shields with an approved type of dark len3 to protect themselves against harmful light rays and sparks <> 2* Only experienced men should operate acety lene generator* Keep open flames away from it* Make certain that the generator is filled with water at all times* Acetylene or Propane Burning and Welding 3* Oxygen cylinders should not be stored near combustible material* Acetylene, oxygen and propane cylinders should not be stored near stoves, radiators or furnaces* Heat will increase the pressure j it can melt or blow the safety plug with which all cylin ders are provided* 4* Do not store oxygen cylinders in a closed place with acetylene or propane cylinders* 5* Store cylinders away from working areas. Keep only enough near the work to insure an adequate supply of gases for the job at hand. 6. Cylinders should be kept far enough away from the actual welding or cutting opera tion so that sparks or flame will not reach them. 7* Cylinders should not be left near furnaces or other hot equipment overnight* Move them a safe distance away. 8. Secure cylinders 30 they cannot be knocked over. C?0 035144 f WELDING SHOP 21-2 / 9. Place cylinders so their valves can be reached quickly. 10. Close cylinder valves during noon hour, at the end of the shift and -when the job is finished. 11. Close cylinder valves tightly when bottle is empty. 12. Do not move cylinders without first remov ing the regulators, unless they are to be carried on an approved carrier. Place caps back on cylinders after removing regulators. 13 When lifting either acetylene, oxygen or propane cylinders with a crane or derrick, use a cradle. Never use slings. 14. Stand acetylene or propane cylinders on end. Oxygen-Acetylene Operators 15. Keep equipment and valves in good order; leaking gas is a fire hazard. 16. Close defective valves on oxygen, acetylene and propane drums, then tell supervisor of defective valve so cylinder can be repair ed. When cylinders are not in use, replace caps. 17. Do not hammer on any kind of drum valve to open or close. 18. Open cylinder valves slowly; be sure that pressure adjusting handle on regulators is fully released. Is T *' 035145 * WELDING- SHOP 21 - 3 19o Leave acetylene gauge wrench in place on the cylinder at all times while in service. 20. Do not try to thaw out frozen acetylene or propane tank valves with a flame or hot iron. . The safest method is to use steam or hot water. 21. Make sure that torches, regulators and hose are in good condition and that all connec tions are tight. 22. Do not force on connections which do not fit. 23. When a new cylinder is connected to the apparatus, always open the blow-pipe valve long enough to expel any air from both hoses before lighting. 21. Blow out drum connection before attaching regulator. 25. Keep hose clear of falling hazards; do not allow hose to become a tripping hazard on stairs or sidewalks. 26. Allow no material to be put on top of a hose while it is in service. In crossing walk ways, carry hose overhead or supply protec tion for the hose. 27. Do not use matches to light the gas blow pipe. Use approved lighters. 28. Shut off valves on torch immediately after a backfire - first,, the oxygen, then the acetylene. Check valves to see that gases are shut off when torch is not in use. WELDING SHOP 21-4 29. Keep oxygen away from oil or grease. Oil or grease in the presence of oxygen under pressure will burn violently. Oily or greasy materials should be kept away from cylinder valves, couplings, regulators, hose and apparatus. Do not handle oxygen cylinders and apparatus with oily hands or gloves. Oxygen cylinders should never be placed in a position where oil or grease is likely to fall on them. A jet of oxygen should never strike an oily surface, greasy clothes, or be allowed to enter any vessel containing oil or gas. 30. Never use oxygen as a substitute for com pressed air. Burning, Welding, Cutting and Hot Work 31. Cover sewer catch basins or openings if your hot work job is near or above them. 32. Articles placed on welding table or jacks should be well braced and laid out to pre vent falling from table, 33 When cutting with acetylene or propane flame, protect legs and shoes from hot metal. 34. Keep flames, sparks, molten slag, and hot metals from coming in contact with materi als that burn or explode. 35. Vent and gas-free all hollow objects before applying heat. 36. Do no cutting or welding using an improvis ed work bench - such as a barrel or drum. 1 035*4? \ \ \ .. WELDING SHOP 21-5 37 Wear a fume respirator if objectionable fumes are produced from melding or burning on brass or other metals. 38. When welding galvanized or monel metals, control fumes 30 they will not be inhaled by the operator - or use approved safety equipment provided. 39. Whenever possible, when working at a height, weld from scaffolding. 40. If welding or cutting is to be done in a hot still or tower or where there is any likelihood of the hose being cut or burned, insulate with another material to protect it. 41. When working in a closed space, see that no compressed gas or oxygen escapes into that space. Leakage of compressed gas can mean an explosion. Free oxygen easily absorbed by clothing, and later contact of a spark with clothing may result in serious burns. 42. ?<hen working in a closed space, always have someone present viio knows how to close the cylinder valves and can render help in case of emergency. 43. Never take cylinders inside of towers or vessels in which work is being done. 44. When work is being done on the inside of a closed vessel and operator leaves the vessel for noon hour, end of shift, or end of work, he should first shut off torch valves and then remove torch and ho3e from inside vessel. p 035148 WELDING SHOP 21-6 Electric folding 45. Temporary power lines to portable arc weld ing machines must be carried overhead. 46. Arc welding sets shall be located in places free from vapor3. When placed within the battery limits of operating equipment, the location shall be approved by the process operator in charge of the equipment. 47. Before plugging in or removing the 440-volt connection, open the power line switch to prevent a flash. Take care to see that the 440-volt plugs are dry and that all cable sections are properly joined and dry. When operations are stopped during the shift or at the end of a work day, turn power line switch off and disconnect power line switch at pole. During noon hour and temporary shut-down3, stop the motor on the welding machine. Do not handle the 440-volt lines without a safety stool.' 48. Electric welding units (not gasoline-driven units) must be grounded through the frame of a rod driven in the ground. This connec tion need not run to the object being weld ed, as it is for the 440-volt side of the welding unit. 49. When using gasoline-engine driven generators, check with the Safety Division before locat ing them. 50. Portable welding units should not be moved until the power is shut off at pole. WELDING SHOP 21-7 51. Machine grounds should not be made to hand rails, steps, or to projections from re ceiving houses, pump houses, or any active gas, oil, steam, air, or chemical line. .Grounds should be made the shortest dis tance from the job. Work grounds should be made to the object being worked on when within the battery limits of operating equipment in service. 52. When dragging cables, take care that in sulation is not cut by sharp objects. 53. Keep welding cables as dry as possible at all times. 54- Wear gloves to protect the hands from burns caused by the splatter of metal. 55 Use protective devices to avoid burns from hot scale. 56. In electric welding, all parts of the body should be covered to prevent skin burns from ultra-violet rays. 57. Where electric arc welding is done in the vicinity of other employees or in the path of traffic, the operation should be sur rounded by approved shields to avoid eye injury to possible onlookers. 58. When cutting or welding in high places and falling sparks and metal endanger men or equipment - provide a method of catching sparks and metal. : i, V - (\ r l Vch 35J 51 WHARF 1. All vessels shall be grounded. Ground shall be maintained until after cargo hose is re moved . A. The following is the exact procedure for connecting and disconnecting the static wire: (1) When connecting hose: a. See that switch is open. b. Connect static wire to ship. c. Close switch . d. Connect cargo hose. (2) When disconnecting cargo hose: a. Disconnect and remove cargo hose from ship. b. Open switch. c. Remove static wire from ship. 2. During loading and discharging warning signs shall be displayed: A. Warning sign at gangway DANGER THIS VESSEL HANDLING PETROLEUM NO FIRES NO SMOKING NO VISITORS B. Red warning signals A red flag shall be displayed by day; an all-around red light shall be displayed at night. 3- Scuppers should be properly plugged before U35I52 WHARF 22-2 vessel is ready for loading and should remain so during the entire time that cargo is being loaded or discharged. k. When loading, ' discharging, ballasting, or cleaning tanks, all main deck doors and ports to quarters shall be kept closed. Upper deck doors and ports facing the main deck also , .should be kept closed when possible. 5. Tank covers should not be opened except under the supervision of the .officer in charge. At all other times tank covers should be closed .while transferring .cargo. 6. No ullage holes should be opened or remain open without flame screen arrestors, except under the. supervision" of the officer in charge. At all other times these openings should remain closed. 7. At ail times when vessel is at wharf it should be moored so as not to endanger either wharf, hose or vessel. 8. A .representative of the wharf should be in constant attendance on the dock at all times when a vessel is transferring cargo. 9* When proper connections have been made and the ship's officer has notified wharf repre sentative that valves are checked and the vessel is ready for cargo, the wharf valves shall be partly opened. Loading .should start slowly and one grade at a time. When it is seen that loading is going .correctly, then the wharf representative should be notified to.load at maximum safe speed. When pressure is being built up on hose, all joints should be watched for leaks. Pumping pressure i\ r\ ^ WHARF 22-3 should not exceed 100 pounds pressure on hose* 10. Transfer of cargo and ballast at the same time is prohibited except in an emergency or with the full knowledge of the wharf representative, master of the vessel and the Safety Department. 11. Loading or discharging bulk petroleum products or ballasting after carrying Grades A, B, .or C products is prohibited during severe .electrical storms. 12. Over-all loading, of Grades A, B, or C .cargoes is prohibited. All other -grades-, including lube stocks, must be with the full knowledge and consent of the wharf representative,.master of the vessel and the Safety Department. 13. All loading hose which has carried kerosine or lighter products shall be displaced with carbon dioxide. 14-. Package freight shall not be loaded or dis charged during the transfer of Grades A, B, or C products except with the full knowledge and consent of the wharf representative, master of the vessel and the Safety Department. 15. All repairs -to be done with strict adherence to the United States Coast Guard laws, and in con junction with the wharf safety rules and reg ulations, and then only with the full knowledge of the wharf representative, master of the ves sel and the Safety Department. 16. Every effort shall be exercised to prevent tugs or other craft from .coming alongside or within 50 feet of a vessel which is transferring in flammable or combustible products. Should this be necessary, all loading in the vicinity will stop. MAGNOLIA PETROLEUM COMPANY r~-J LIKE A LOT OF OTHER TH IN G S .......... J ............ 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