Document zQYyOewvM2n6yamJ6J0pXpNGn
PSM COMPLIANCE
The focus used on implementing CFR 1910.119 is the protection of our employees, our equipment, our neighbors, and the environment.
Nine Safety Teams have been established from all disciplines in the refinery to assist the overall safety effort and monitor compliance and improve implementation of 1910.119. They are Total Involvement; Safety and Health Rules and Procedures; Emergency Response; New/Altered Equipment Acceptance; Safety and Health Auditing; Safety Motivation and Accountability; Serious Incident Investigation; Contractor; and Process Hazards.
The following is a summary of how we are implementing the various portions of CFR 1910.119 at Koch Refining Company's Corpus Christi refinery, with the responsible party and Safety Team listed in parentheses.
1. Employee Participation - A written plan entitled "The Safety and Health Process" has been developed. Employees from different areas of the refinery, and in different levels of those areas, are involved in developing and updating information and making that information available to those who need it. The Refinery Quality System involves all disciplines in the effort to produce consistent high quality products. (The Refinery Manager, Central Safety and Health Council, Total Involvement Team, Safety Motivation and Accountability Team, Quality Coordinator)
2. Process Safety Information - Existing information is being verified, corrected, and collected in a central location to facilitate access to it. (Hazard Analysis Coordinator, Design Drafting Supervisor, Process Hazards Team)
3. Process Hazards Analysis - A team composed of Koch employees, including a trained Facilitator, Operations representative, Process Engineer, Refinery Engineer, Supervisor, and any other groups required, takes the updated PSI and analyzes the process. (Hazard Analysis Coordinator, Process Hazards Team)
4. Operating Procedures - Each Process Control Room has either completed, or is in the process of completing, an Operating Procedures Manual for the area. These manuals include all processes in the unit, whether or not they are covered by the regulation. (Processing Manager)
5. Training - Training begins at employment and continues for the duration of one's career. Results of the training classes are documented and retained. Formal and periodic training is given in Process and Procedures. Training is also given on shift. (Training Coordinator, Total Involvement Team)
6. Contractors - Contractors are expected to conform to API-RP 2220. The Contractor Safety Coordinator is responsible for auditing performance. (Refinery Engineering Manager, Contractor Team)
7. Pre-Start-Up Safety Review - A study is conducted for new units, major revamps, or new processes to make certain those who operate the equipment or perform maintenance work on the equipment are aware of the proper operating or maintenance procedures. Training is done prior to commissioning. (Process Engineering Manager, New/Altered Equipment Acceptance Team, Process Hazards Team)
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8. Mechanical Integrity - All equipment is operated and maintained within safe limits. People who maintain equipment are trained to perform testing and inspection. Only acceptable quality replacement parts are used. Frequency of tests or inspections is determined by the manufacturer's recommendation or past history. (Maintenance Manager, New/Altered Equipment Acceptance Team)
9. Hot Work Permit - Our Hot Work Permit uses a checklist format to ensure that the affected area is isolated, safe and ready. It further ensures that Safety, Operations, Maintenance, and Contractors are aware of the work being done and any special circumstances regarding it. This permit has been expanded to include "Cold Work" as well. The emphasis being that all work is conducted in the safest possible manner. (Safety and Health Manager, Safety and Health Rules and Procedures Team)
10. Management of Change - Any change other than replacement in kind that affects the safety of the process is reviewed by three separate groups for safety, necessity, and advisability before being implemented. PSI is updated when a change is made. (Hazard Analysis Coordinator, Process Hazards Team)
11. Incident Investigation - All accidents, near misses, etc., are investigated within 48 hours by a safety team which has been formed for that purpose. Contributing factors are identified and communicated to all affected personnel. (Health and Safety Manager, Serious Incident Investigation Team)
12. Emergency Planning and Response - An Incident Command System is being
implemented to respond according to any type of emergency. ERT members receive training enabling them to deal with all emergencies likely to occur. In addition, alarm systems are in place and the employees and community are educated in their use. (Emergency Response Coordinator, Emergency Response Team)
13. Compliance Audit - There are various internal audits conducted. Different groups routinely perform self-audits to improve performance. Others are brought in periodically for objectivity. An audit team will evaluate and certify compliance with 1910.119 annually. (Refinery Manager, Support Services Manager, Safety and Health Auditing Team)
14. Trade Secrets - Any information regarding health, safety, or operation of processes or equipment is made readily available to those who need it. (Refinery Manager, Total Involvement Team)
LDS/syw 1/28/93
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WHY A SAFE WORK PERMIT 1. Required To Have And Document Process Over View
1910.119. 2. Need To Assure Chemical Hazards/MSDS Reviewed
1910.1200. 3. Emergency Procedures And Accountability 1910.38. 4. Reduce Number Of Individual Paper Work Documentation. 5. Easier Method Of Documenting Lockout/Tagout Procedure
(OSHA Settlement). 6. Hazards Of Each Job And Process Must Be Reviewed
1910.119,1910.1200 And OSHA Settlement. 7. Increases Safety Awareness And Compliance. 8. Improve Communication. 9. To Allow Operations To Know Every Job Being Don In Their
Area. 10. To Allow Operations And Maintenance To Have A Positive
Method Of Reviewing All Safety Preparations For The Work To Be Performed.
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Case cf Emergency cifv Area Process Personnel fetv Dead cr Call t. 8596 or 8797
SAFE WORK PERMIT
KOCH REFINING COMPANY Corpus Christ! Refinery --
Dace//_
AM Time_?K
Karnes cf evervone who will work on this job must sign in on the pink copy cf this oermit. --e safecv Dead is responsible for,communicating all elements of the Safe 'work Permit to
his/her crew.
C NIT / D o c a t i or.
Equipment-
K. O. /A.FEr________________________________
-- Cost Center#
Job Description:_______________________________
-- s Permit is only valid for 24 hours. After 24 hours new permit mus t be is irs work permit pink copy shall be returned to Safety &_ Health.
Saf e Work Permit Checklist: (A) Process Overview completed (3) Chemical Hazards Identified and MSDS Reviewed:
!C) Kill Energy Control Program Be Required:
Yes No N/A. Yes No N/A Yes NO N/A
Equipment Depressured
Yes No N/A
Equipment Cleared
Yes Ko N/A_
Energy Source Docked and/or Tagged Out
Yes No N/A
Energy Source Tried
Yes NO N/A
Energy Source Blinded cr Isolated
Yes No K/A
(=>) Help From Other Craft Needed (Electrician, Insulators, Scaffolcers, Etc.)
Yes Ko N/A
(3) Emergency .Action and Equipment/ Identified
Yes Ko N/A
(3) Is Eye Wasn/Safety Shower Operable
Yes Ko N/A
(C) Hot Work Permit Procedure Followed
Yes NO N/A
(H) Confined Space Permit Procedure Followed (-) Hot Tap Authorization Completed (-') Excavation Identification Form Completed
Yes No N /A Y'es No N/A Yes Ko N/A
(K) Critical Dift Authorization Completed
Yes No N/A
(3) Safe For Motorized Equipment Entry
Yes No N/A
.ny <sf the above questions are answered No, the Safety Deads Superv isor must i;
'he
Check Personal Protective Equipment Needed:
______Respirator
_Breathing Air Fall Protection ______Barricades
Class of Clothing A B C D
____________Ground Fault Interrupter______Goggles/Faceshield
_____________Hot Sticks
__Hearing Protection
______Wooden Clothes Pins
______Insulated Blankets
Any Other Special Placards and Precautions:_____________________________
d*n
Rubber Gloves Flash Co (Blast
Sweety Dead:______ Safety Dead (Relief):
Process Persor.nel/Owner: Process Perscr.nel/Owner (Relief):
Revalidation: Process Personnel/Owner:___________________ Safety Dead:
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Issued Hy Accepted Bv Rcsponsinmtv Transtcred To (NamejT Plant Suni. Sicnaturc (If Rcnuircdi. _
SAFE WORK MULTI-PERMIT
LOUISIANA DIVISION M90 L0S7 n
Date. Time From.
To_
Co-Siener Sen.iturc________
.am.
_n m
Complete Sell hmi I t.it all permit*. Completion nt Section i ()M.\ indicates mat Mink is vunitolkd In departmental pioivUiirus. Completion of Sections 11. lit and/or IV requite an On-Site InsfK-oioo.
I. Work Limited to the Folhmitu:: (Description A Area/ Lqinpincuc I.
SECTION 1
GENERAL WORK PERMIT
The Following Have Been Reviewed with Joli Supervisor:
A Salctv Shower. Eve Wash - Location A. use B Emergency alarms. Evacuanon. Asscmmv Point c. Procedure for Sale Job Completion . . D. Have tools &. equip, of outside contractors nccn inspected E. Have all comract/Dow personnel received Salctv Uucmaiion F Additional Permits Kcuuircd (Litting. Hoi lap. cu.i G Scaffolding m Compliance tKef E*0)
G Ye*
G Yes G Oral _ 'i c. _ Yes _ Yes G 'tes
NA
__ V. rmen . N A .. N A _ N.A .. N A
S|>eciai Exposure to Protect Against: ... None
Chemical tiuTmei
--
G Flammable
G Corrosive
G Pressure Extreme
G Toxic
O Reactive
G Thermal Burn
G Skin Contact
G Hot Water/Steam G Noise
G !nen Aunosnnere C3 Radiation
G Other -........ - - .
Falls Electrical
_ Heat Stress O Asoestos
4. Safety Equipment: (Other than area requirements): LJ None
G Slicker Suit
Chemical Goggle* O Canister Mask
G Cliemical Suit
D Face Shield
Ll Supplied Air
G Rubber Boots
Hood
G Air Pack
G Gloves ^
Q Safety Harness
G Outer: ______
G Heanne Protection D Ground Fault Circuit Intcrnmicr
C Barricades f 1 Flash Suits
5. An On-Site Inspection Connuctcd. . .G Vcs G N
initials ot Inspector
SECTION H
OPENING LINES OR
EQUIPMENT EXCAVATIONS
ETC. (See S-301)
SECTION 111
HOT WORK
(Sec S-301 & S-JI21
SECTION IV VESSEL ENTRY
Excavation (4* or deeper refer to S-301) (Set* S-301 &
S-302)
SPECIAL INSTRUCTIONS PRECAUTIONS LIMITATIONS
Complete this Section and Section I for Opening lanes Equipmcnt/Excavation*.
1. Equipntem Drained/Oenressured. . 2. Equipment Purged/Cleaned...................................................................
3. Fuses Kemoyed/Switcnes ooen...............................
.........................
4 Lock Rcuutreo (List on Red Tag Masteri. .
5. Field Switches Tested.................................................
.........
6 Red Tacs Attached tRefcr S-303) (Master #-------------------)
7 Line Positively Idcmtfied/lnmaled (Refer S-301)
S. Adjacent Area Safe (If Limited. Dcscrmc Belowi.........
9. Area Roped Off.................................... ................................. ...
10. Bhnds/Block & Bleed m mace (List blinds on Red Tag Master)
11. Excavation Sale to perform (Rcler S-301)..................................
*2 Blue Flue in use on RR Tracks (Rcter S-MV>)
Complete this Sccthm and Section* I and II for llot Work Salety Observer iRef. C*l) (Name) , Ftrc Exttnguisncr* Type:. Fire Blankets (Location). Water Fog (Utcaunn)_
5 Puree (Gas Used) ___ o. Heat exposure to Gasket. Seals. Liners. (Dcscrmc Precautions). 7. Other Work in Area wmcb should be Stopped (Dcscrmc Ikinwj R. Material Present winch Emits Vapor when Heated iDcsctthe Belowi 9. Pipe stoppers in Use (Refer Salety Rcl a a-6) 10 Equipment Operating or Contains original Contents.
(11 Yes. Written procedures are reomred &. Plant Sunt, must Co-Sign Permit) 11. Adjacent Areas Safe (ll Limited Dcscrmc Below). 12. Expkttimctcr. Oxygen Tests Acceptable......... 13. Ground lead aitacned to wns, ......
(Iksmhr bekwr specific kratwMi wtxrr LEL. 0, tests are to )w conducted 4 Trvl ratnencvl
N.A. :
l
Nil I
ii
"i
G
G g
!i
C
Complete this Scctmn and Sections 1 and II for Vessel Kntrv
i Radioactive DcvM.es Sloeiucd and lapsed 2. Procedure and Kguinmem mr Rescue on job Sue.
' Ventilation installed anu Grounded 4 Salctv Observer Provided (Rel C-1) (Namci _
Hazardous Material on Wulls or Bchmu Liners CoiimociciI
LEI.. O4.. PPM Acccmanie (l.EL-0%) <0; 19.?*; -n TLVPPMpH
ip.tuer Actual)
Vessels hhndcd tlionoie Blocks A lileetis reunife .ippiovah
Is Vessel entry Tuner available..
..
Has Securuv Iteen notified o) Rescue Plan
llhirnlw Iwkm snrnfir Inraimm wnrrt l.KL. 0. aod PPM leM* are In k* conducted & hrniuettcvi
Ktticr Special Instructions, Precautions. Limitations fur ail Sect inns (I thru IV)
NSC-91-91 Page 14
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