Document zz938Jn9bQxX6BdozwqKzdyz7

\ v.-.'Ua. * MONSANTO COMPANY ANNISTON PLANT .. . STANDARD OPERATING INSTRUCTIONS FOR AROCLORS November 1969 025010 738265 WATER PCB-00049441 STANDARD OPERATING INSTRUCTIONS FOR AROCLORS SAFETY AND HOUSEKEEPING ' Safety of operations in the Aroclor Plant depends on the individual operator. Materials- being handled and operations must be observed closely to guard against the following? Cause and Action to Prevent 1. Chlorine Gas Chlorine gas is a very toxic corrosive gas. Leaks or high pressure can occur to liberate it. . Action to Prevent a. Report Chlorine gas exposure immediately for treatment with Antidote. Milk may be used in mild cases to relieve throat irritation. Oxygen from the resuscitator in the Dispensary is available. b. Keep gas mask in good condition. Keep a good canister in the mask. Use these type masks only in chlorine concentrations . to 2-37. chlorine in air. ' ' c. Use a Scott Air Pak in concentrations of Chlorine gas above 3% in air, Three units are available in the Aroclor-Biphenyl Department. d. If caught in chlorine gas without a mask, hold your breath and go cross wind until you are out of range of the gas. Place a handkerchief over your nose in small quantities of chlorine. e.' Report all chlorine leaks for repair immediately. Make temporary repairs with tape if possible. , In case of a major chlorine leak, the source of chlorine gas must be stopped. Cut off chlorine from cars. NEV 025011 738266 WATER PCB-00049442 Aroclors Safety & Housekeeping 2. Thermal Burns . 2. Cause and Action to Prevent Contact with hot uninsulated product lines at the chlorinators and still areas. Contact with uninsulated steam lines and open steam. Contact with hot Aroclors from broken lines or leaks. Contact with open flames at stills or from heating lines in the department. Action to Prevent a. Know that contact with equipment and product will cause a thermal burn due to the high temperatures. Make changes in operations with this hazard in mind. b. Know the first aid treatment for burns. Cold Water Treatment (See Appendix A Emergency Section). c. Wear gloves and long sleeve shirts with the sleeves rolled down when operating. Gloves and clothing can make the dif ference between first and second degree burns. d. Report uninsulated lines for repair o Insulation. e. Use only steam lines with hose and hose clomps in good condition. f. The following operations are hazardous and should be done with care: (1) Catching samples at the Aroclor chlorinator circulating lines. (2) Sampling the Solid Aroclor still receiver. (3) Drawing bottoms on the Aroclor stills. Q2S012 738267 WATER PCB-00049443 Aroclors Safety & Housekeeping 3. Explosion A. Falls 3. Cause and Action to Prevent An explosion could occur in the chlor1nators by slugging liquid chlorine to the distributor. Slugs of liquid chlorine could react fast enough to cause excessive pressure in the vessel. A rupture of the chlorinator could occur. Action to Prevent a. Observe operation of the chlorine vaporizer and do not let liquid chlorine get into the rotameters. Pipe lines will be frosted. b. In case chlorine feed lines are frosted, close liquid chlorine feed valve to the vaporizer. Check steam addition to the vaporizer. Do not start up until source of trouble has been located. c. Do not close valve in water discharge line from the chlorinator coil. d. Observe temperature of the chlorinator periodically and be sure it is not too hot (180C. maximum). Slipping on cement floors, stairs, Aroclor on floor, ice conditions; tripping over objects (hose, pipe, valve handles , etc.) ; or losing footing on ladders, etc., can cause falls. Action to Prevent a. The majority of minor, serious, and near-miss injuries in the Aroclor Dept. are the result of falls. Prevention is always within the ability of the operator by use of expert operating practices. NEV 025013 738268 WATER PCB-00049444 Aroclors Safety &. Housekeeping (Contd.) - . 5. Fires . A. Cause and Action to Prevent b. The following items should be done: (1) Return hose to rack after using. (2) Keep operating areas clean of all foreign objects. (3) Return ladders to racks when not in use. (4) Keep gloves on and hands out of pockets, especially going up and down stairs. (5) Place guards around any area that presents a hazard that should be guarded. c. Poor lighting due to burned out bulbs should be corrected at once. Poor lighting due to inadequate facilities should be reported. d. Spills must be cleaned up immediately following their occurrence. Report any spill that cannot be cleaned up within the shift to the Chief Operator. Spills , are to be reported in the log book. Fires can occur by: Biphenyl, Santowax R, or Santowax C ignition. Chlorine problems in the vaporizer allow ing reaction with steam to release hydrogen. Furnace burner backfire. Wood, rags, or paper on hot lines. Sparks from welding apparatus of open flames. NEV 025014 738269 WATER PCB-00049445 Aroclors Safety and Housekeeping 5. Fires (Contd.) - . . 5. Cause and Action to Prevent Action to Prevent a. Area must be clear of trash or flam mable materials. Use trash skips and . cans. b. Smoke only in areas so designated. c. Use spark producing equipment only with a fire permit and proper in spection. d. Use care in lighting gas torch or the still furnaces. e. Fire fighting equipment includes: (1) Two wheeled dry powder units, (2) Hose house with 200 ft, of hose. (3) Two dry powder hand extinguishers, One CO2 hand extinguisher. (A) Two 3/4" water hoses. (5) Hose connection north of Santov/ax. (6) Scott Air Paks. (7) Fire truck in fire house. f. Observe visitors in the plant and be sure they observe safety rules. NEW 025015 738270 WATER PCB-00049446 Aroclors Safety nnd Housekeeping 6. 6. The following is a list of chemicals handled in the Aroclor Plant operations and the precautions to be taken during their handling: a. Chlorine Gas This is a corrosive gas which is toxic. Leaks or back pressure can occur and liberate chlorine gas in the area. ' Operators should have their cartridge type respirators handy at all times while in the area. Use of gas masks is explained in Section B.1. If you are caught without a gas mask, and large amounts of chlorine gas are liberated, hold your breath and go cross wind until you are out of range of the gas. Once out of the area, obtain an emergency gas mask and - return to the area and correct the trouble. A victim of chlorine gas fumes must be removed as quickly as possible from the gaseous area. Place patient on his back with head and back elevated. Milk may be used in mild cases as a relief from throat irritation. If the patient has stopped breathing, start artificial respiration immediately. b. Biphenyl Biphenyl is a flammable material which will burn. Burning should not be done in the presence of Biphenyl or Biphenyl vapors. The melting point Is 68,7C. , and the auto ignition temperature is 258C, Inhalation of Biphenyl fumes is not recommended, since it can cause a drugged effect on the person. c. Santowax R Santowax R is a flammable material which will burn. It is relatively non-toxic to human beings. However, the vapors of Santowax R are irritating to the mucous membranes and broniehial tract. Pro longed breathing of the vapors should be avoided. The melting point is 140C. d. Santowax C Same as Santowax R, since it is the crude material prior to distillation. NEV 025016 738271 WATER PCB-00049447 Aroclors Safety & Housekeeping I 7. 6. (Continued) e. Ferric Chloride Ferric Chloride is a black-brown solid. It causes only slightly irritating effects on the skin or mucous membranes. When heated it will decompose and release toxic fumes of chlorine. It will react with water to produce toxic and corrosive HCl fumes. f. Attapulgus Earth This material is a dried earth. No danger in handling. Wash off with water to clean. g. Hydrated Lime No particular hazard in handling this material. The dust is irritating to the eyes and skin, and should be washed off with water. h.' Crude Aroclors Crude Aroclors are hot, since all are handled in steam traced or jacketed < lines. They can easily cause thermal burns in contact with the skin. Prior to air blowing, the material has HCl fumes entrained in it which are irritat ing to the skin or mucous membranes. i. Hydrogen Chlorine Gas This is a corrosive gas which is toxic. It is irritating to the mucous membranes, to the eyes, and to the respiratory tract. It will react with water to form Hydro chloric Acid, J. Still Bottoms or Residue Fumes from still bottoms are toxic. They are extremely irritating to the mucous membranes, to the eyes, and respiratory tract. NV 025017 738272 WATER PCB-00049448 Aroclors Safety & Housekeeping 8. HOUSEKEEPING The Aroclor chlorinator and still operators arc responsible for house keeping during their shift. Good housekeeping is the mark of good operations, safety practices, quality, and costs. Housekeeping duties are equal in importance with all other operating duties. Poor Practices . Hoses, valve handles, dip sticks, rags, and other material on ground or floor. Action to Prevent a. Replace after use. b. Have place to store all necessary .operating aids. c. Report needs to supervision. Product Leaks. a. Tighten valve pocking glands and flange bolts. b. Report leaks to Chief Operator for maintenance alteration. Trash and Crude Drums. a. Contact Chief to have drums moved from area. b. Use trash skip in area. Product spills or clean out messes. a. Prevent necessity of clean-out by keeping tracing, insulation, or jacket in good repair by getting items turned in for maintenance work. b. Spills must be cleaned up when they are made. Clean up will continue through the following shifts to finish the job. NV 025018 738273 WATER PCB-00049449