TASK: OPEN/CLOSE PRODUCT ACID VALVE 5 … TASK: START UP SULFUR PUMPS ... 5 Job Safety Analysis...

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TASK: OPEN/CLOSE PRODUCT ACID VALVE .......................................................................................................................................................................................5

TASK: DIP IPA AND FINAL PUMP TANKS...............................................................................................................................................................................................6

TASK: CATCH ACID SAMPLES AT PUMP TANKS................................................................................................................................................................................7

TASK: FILL PUMP TANKS WITH ACID ( AFTER T/A ) ...........................................................................................................................................................................8

TASK: TRANSFER ACID FROM ONE PLANT TO ANOTHER................................................................................................................................................................9

TASK: DRAIN ACID SEAL LEG..................................................................................................................................................................................................................10

TASK: START UP ACID CIRCULATING PUMPS. ...................................................................................................................................................................................11

TASK: SHUT DOWN ACID CIRCULATION PUMPS. ..............................................................................................................................................................................12

TASK: ADJUST ACID FLOW OVER TOWERS.........................................................................................................................................................................................13

TASK: STICK TEST ON TOWERS...............................................................................................................................................................................................................15

TASK: PUMP OUT CIL COOLERS. (ACID SIDE).....................................................................................................................................................................................16

TASK: DRAIN CIL COOLERS (WATER SIDE). ........................................................................................................................................................................................17

TASK: BACK FLUSH CIL COOLERS(WATER SIDE). ............................................................................................................................................................................18

TASK: CAUSTIC WASH ACID TOWER. ....................................................................................................................................................................................................19

TASK: BYPASS DILUTION TANK..............................................................................................................................................................................................................20

TASK: VALVE IN BOILER SIGHT GLASSES. ..........................................................................................................................................................................................21

TASK: VALVE OUT BOILER SIGHT GLASSES. ......................................................................................................................................................................................22

TASK: BLOW BOILERS DOWN MANUALLY. .........................................................................................................................................................................................23

TASK: DEPRESSURE AND DRAIN BOILERS. ..........................................................................................................................................................................................24

TASK: CHECK BOILER LEVEL TRIP(PLANT SHUTDOWN)...............................................................................................................................................................25

TASK: PUT OA SUPERHEATER IN SERVICE..........................................................................................................................................................................................26

TASK: PUT 4A SUPERHEATER IN SERVICE...........................................................................................................................................................................................27

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TASK: DEPRESSURIZE SUPERHEATER. .................................................................................................................................................................................................28

TASK: BACK SATURATED STEAM INTO PLANT..................................................................................................................................................................................29

TASK: PUT FLASH TANK IN SERVICE.....................................................................................................................................................................................................30

TASK: DRAIN ECONOMIZERS. ..................................................................................................................................................................................................................31

TASK: START UP KEYSTONE BOILER. ...................................................................................................................................................................................................32

TASK: RUN SULFUR GUN SURVEY...........................................................................................................................................................................................................33

TASK: VALVE OUT STEAM ON SULFUR GUNS. ....................................................................................................................................................................................34

TASK: UNPLUGGING SULFUR GUNS. .......................................................................................................................................................................................................35

TASK: PUT SULFUR GUN IN SERVICE.....................................................................................................................................................................................................36

TASK: PUT STEAM ON SULFUR GUNS.....................................................................................................................................................................................................37

TASK: START OIL FIRE. ...............................................................................................................................................................................................................................38

TASK: WATCH OIL FIRE ON HEAT UP....................................................................................................................................................................................................39

TASK: CHANGE OIL TIP DURING OIL FIRE HEAT UP........................................................................................................................................................................40

TASK: CHANGING FUEL OIL FILTERS DURING OIL FIRE HEAT UP. ............................................................................................................................................41

TASK: ADJUST PLANT DAMPERS..............................................................................................................................................................................................................42

TASK: OBTAIN PLANT READINGS. ..........................................................................................................................................................................................................43

TASK: CHECKING STACK DRAIN.............................................................................................................................................................................................................44

TASK: CHECK MOISTURE DRAINS, BOILERS AND ECONOMIZERS..............................................................................................................................................45

TASK: BARRICADE ACID LEAKS..............................................................................................................................................................................................................46

TASK: CAUSTIC WASH MAIN COMPRESSOR. ......................................................................................................................................................................................47

TASK: SHUT DOWN MAIN BLOWER........................................................................................................................................................................................................48

TASK: START UP MAIN BLOWER. ............................................................................................................................................................................................................49

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TASK: START UP #6 FUEL OIL DISPENSING PUMP. ............................................................................................................................................................................50

TASK: START #2 FUEL OIL PUMP............................................................................................................................................................................................................51

TASK: START UP WELL WATER PUMPS. ...............................................................................................................................................................................................52

TASK: BLEACH COOLING TOWER. .........................................................................................................................................................................................................53

TASK: BYPASS FEEDWATER HEATER....................................................................................................................................................................................................54

TASK: START UP BOILER FEEDWATER PUMP. ...................................................................................................................................................................................55

TASK: START UP COLD WELL PUMPS....................................................................................................................................................................................................57

TASK: RUN WATER SAMPLES IN LAB.....................................................................................................................................................................................................58

TASK: ESTABLISH CHLORINATION TO POTABLE WATER. ............................................................................................................................................................59

TASK: START UP COOLING TOWER FANS. ...........................................................................................................................................................................................61

TASK: START UP POTABLE WATER PUMPS. ......................................................................................................................................................................................62

TASK: PUT FEED WATER HEATER IN SERVICE. ................................................................................................................................................................................64

TASK: CLEAN COOLING TOWER SCREENS..........................................................................................................................................................................................65

TASK: PUT FIN/ FAN CONDENSER IN SERVICE. ..................................................................................................................................................................................66

TASK: OBTAIN BOILER WATER SAMPLES...........................................................................................................................................................................................67

TASK: DIP ACID STORAGE TANKS. .........................................................................................................................................................................................................68

TASK: SULFURIC STORAGE TANKS: CLEANING PROCEDURES. ..................................................................................................................................................69

TASK: PREPARE SULFURIC ACID TANK FOR SERVICE AFTER CLEANING. ..............................................................................................................................70

TASK: SWITCHING ACID STORAGE TANKS. ........................................................................................................................................................................................71

TASK: START UP ACID TRANSFER TO PHOS-ACID. .........................................................................................................................................................................72

TASK: START UP AIR COMPRESSORS. ...................................................................................................................................................................................................73

TASK: DIP SULFUR TANKS. ........................................................................................................................................................................................................................74

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TASK: START UP SULFUR PUMPS. ...........................................................................................................................................................................................................75

TASK: DIPPING TANK PIT............................................................................................................................................................................................................................76

TASK: LOCK OUT BREAKER IN MCC......................................................................................................................................................................................................77

TASK: SECURE ACID TANK FOR CLEANING........................................................................................................................................................................................78

5

Job Safety AnalysisSulfuric Acid Plants

Date: 5/19/92Revised: 6/30/97

Written By: LondonReviewed By: MEB

Procedure Number: NWF-JSA-001

Task:Open/Close Product Acid Valve

Work Step Potential Hazards Corrective Action1. Open or Close Block Valve Acid Leaks Wear Acid Jacket, Face Shield, Rubber Gloves and

Goggles.

6


Date: 6/1/89Revised: 6/30/97

Written By: A. TaylorReviewed By: MEB


Task:DIP IPA and Final Pump Tanks

Work Step Potential Hazards Corrective Action1. Go to top of pump tank. Acid burns Wear acid jacket, facie shield, goggles, and rubber

gloves.2. Lower measuring rod into pump tank until it

touches bottom, and remove rod.Acid burns Same as # 1.

3. Check measurement on rod for amount of acidin tank.

Acid burns Same as # 1.

4.

7


Date: 7/24/89Revised: 6/30/97

Written By: P. IannoneReviewed By: M.E.B.


Task:Catch acid samples at pump tanks.

Work Step Potential Hazards Corrective Action1. Obtain proper sample bottles. None None.2. Climb stairs to sample point. Tripping hazards and acid leaks. Watch step, use hand rails; keep walkways clean;

wear acid jacket, face shield, goggles, and rubbergloves.

3. Open acid sample valve slowly and fill samplebottle.

Acid splash or acid leak. Wear acid jacket, face shield, goggles, and rubbergloves.

4. Rinse sample bottle with acid then refillsample bottle.

Acid splash or acid leak. Wear acid jacket, face shield, goggles, and rubbergloves.

5. Secure lid on sample bottle. Acid splash or acid leak. Same as step four.6. Close acid sample valve. Acid splash or acid leak. Same as step four.7. Rinse off acid sample bottle and rubber gloves

with water.Acid splash. Same as step four.

8


Date: 5/11/89Revised: 6/30/97

Written By: K. AndersonReviewed By: MEB


Task: Fill pump tanks with acid ( after t/a )

Work Step Potential Hazards Corrective Action1. Close pump tank drain valves. Chemical burns from acid leaks. Wear acid jacket, face shield goggles and gloves.2. Open acid pump tank equalizing valves. Same as step one. Same as step one.3. Open the transfer valves at plant which will

receive acid.Same as step one. Same as step one.

4. Open transfer valves on plants that will sendacid.

Same as step one. Same as step one.

9


Date: 1/9/90Revised: 7/1/97

Written By:Reviewed By: MEB


Task: Transfer acid from one plant to another.

Work Step Potential Hazards Corrective Action1. Set up valves to plant receiving acid. Acid leaks. Wear acid jacket, face shield , goggles, and gloves.2. Set up valves from plant sending acid. Acid leaks. Wear acid jacket, face shield , goggles and gloves.3. Slowly open hot acid transfer valve off the

IPA header a maximum of two rounds.Acid leaks. Wear acid jacket, face shield, goggles and gloves.

4. Inspect acid transfer line for leaks. Acid leaks. Wear acid jacket, face shield, goggles and gloves.

10


Date: 8/23/90Revised: 7/1/97



Task: Drain acid seal leg.

Work Step Potential Hazards Corrective Action1. Make sure area is barricaded. None. None.2. Make sure acid drain hose is connected and on

pad.None. None.

3. Open acid drain valve. Chemical burns and falling. Wear full acid suit, l face shield, goggles, glovesand boots. Use 3-Point stance on ladder or safetybelt on high reach.

4. Rinse pad with water. Chemical burns. Wear full acid suit, face shield, goggles, gloves andboots.

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Date: 7/15/93Revised: 7/1/97

Written By: K. SamsReviewed By: MEB


Task: Start up acid circulating pumps.

Work Step Potential Hazards Corrective Action1. Check moisture drains. Chemical burns, hand injuries. Wear acid jacket, face shield, and gloves.2. Check cooler exit and bypass valves for

correct position.Burrs on valves. Wear gloves.

3. Check drains on coolers. None. None.4. Check pump tank area. None. None.5. Start acid pumps. Chemical burns. Clear all personnel from area.6. Check for leaks. Chemical burns. Wear acid jacket, face shield, and goggles. Shut

down acid pumps.

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Date: 6/10/89Revised: 7/1/97



Task: Shut down acid circulation pumps.

Work Step Potential Hazards Corrective Action1. Check pump tank level. None. None.2. Clear pump tank area of all personnel. None. None.3. Shut down acid circulation pumps. Chemical burns. Clear pump tank area of all personnel.4. Close product acid valve. Hand injuries, chemical burns. Wear acid jacket, face shield, goggles and gloves.5. Valve out dilution water. Hand injuries. Wear gloves.

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Date: 9/14/92Revised: 7/1/97

Written By: O. JenningsReviewed By: MEB


Task: Adjust acid flow over towers.

Work Step Potential Hazards Corrective Action1. Take stairs to top of pump tank. Tripping hazards and possible acid leaks. Watch step use hand rails. Wear acid jacket, face

shield , goggles and gloves.2. Contact chief operator on radio, open and

close valves as needed.Same as one. Same as one.

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Date: 9/13/92Revised: 7/1/97

Written By: O. JenningsReviewed By: MEB


Task: Pump out pump tanks.

Work Step Potential Hazards Corrective Action1. Open acid pump tank drain valves. Chemical burns. Wear acid jacket, pants, face shield , goggles, and

rubber gloves.2. Open valves on line from pump tank to drain

pump and from drain pump to transfer line outof plant.

Chemical burns. Same as one.

3. Open valves on transfer line into plantreceiving acid.

Chemical burns. Same as one.

4. Start drain pump. Chemical burns. Same as one.

15


Date: 7/16/89Revised: 7/1/97

Written By: K. Taylor/Rick RiceReviewed By: MEB


Task: Stick test on towers.

Work Step Potential Hazards Corrective Action1. Get sticks and mark them. Splinters. Wear gloves.2. Tie sticks on rope. Splinters. Wear gloves.3. Climb ladder to top of towers. Slipping/falling and chemical burns. Maintain three point contact with ladder. Wear acid

jacket, face shield, goggles, and rubber gloves.4. Pull up sticks. Rope burns, falling sticks. Wear gloves. Clear area below.

5. Climb ladder to each tower stick test valve. Slipping/falling. Same as three.6. Open stick test valve, insert stick, time for one

minute, remove stick, and close valve.Acid mist, chemical burns. Wear acid jacket, face shield, goggles, and rubber

gloves.7. Rope sticks to ground. Rope burns, falling sticks. Same as four.8. Climb down from tower. Slipping/falling, chemical burns. Same as three.

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Date: 4/18/89Revised: 7/1/97

Written By: L. SpellReviewed By: MEB


Task: Pump out CIL coolers. (acid side).

Work Step Potential Hazards Corrective Action1. Open valves to pump tank which will receive

acid.Acid leaks/chemical burns. Wear acid suit, face shield, goggles, and rubber

gloves.2. Open valves on CIL cooler drain lines to acid

drain pump.Same as one. Same as one.

3. Start drain pump. Same as one. Same as one.4. After coolers are empty, Shut down drain

pump.Same as one. Same as one.

5. Open expansion joint drain to pad. Acid splatter. Wear acid suit, face shield, goggles, rubber gloves,and boots.

6. Wash pad with water. Acid splatter. Same as five.

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Date: 5/11/89Revised: 7/1/97



Task: Drain CIL coolers (water side).

Work Step Potential Hazards Corrective Action1. Close inlet water valve. Burrs on valve wheel or chain operator. Wear gloves.2. Close outlet water valve. Same as one. Wear gloves.3. Open drain valves. Burrs on valve handle. Wear gloves.

18


Date: 2/11/90Revised: 7/1/97

Written By: C- ShiftReviewed By: MEB


Task: Back flush CIL coolers(water side).

Work Step Potential Hazards Corrective Action1. Close inlet and exit valves to coolers. Rough handles and chain operators. Wear gloves.2. Drain water from coolers. Rough valve handles. /wear gloves.3. After doors are removed, open exit water

valve to backflush cooler.Rough valve handles and chain operators. Heavyvolume of water out of south door.

Wear gloves clear area, Post watchman.

4. Close exit valve. Same as one. Wear gloves.

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Date: 5/14/89Revised: 7/1/97

Written By: T. Mc BrideReviewed By: MEB


Task: Caustic wash acid tower.

Work Step Potential Hazards Corrective Action1. Position caustic tanker. Moving truck. Stand clear of load and chock wheels when

positioned.2. Set up caustic hose and air line. Hand injuries , and back strain. Wear gloves and use proper lifting techniques.3. Inspect pump tanks for acid. Chemical burns. Wear acid jacket, face shield and goggles.4. Fill pump tanks with well water. Hose flipping out. Tie hose into tank.5. Open caustic valve on tanker for

approximately five minutes.Chemical burns. Wear acid suit , face shield, goggles, and rubber

gloves.6. Close seal leg drains and CIL cooler drains. Hand injuries , chemical burns. Wear acid jacket, face shield, goggles, and gloves.7. Circulate caustic water over towers. Chemical burns. Barricade all leaks.8. Sample water. Maintain 8-9.5 ph while

circulating.Chemical burns. Wear acid jacket, face shield, goggles, and rubber

gloves.9. Drain all caustic water from pump tanks, seal

legs, and CIL coolers.Chemical burns. Wear acid jacket, face shield, goggles, and rubber

gloves.10. Remove caustic and water hoses. Hand injuries , back strain, and chemical burns. Wear acid jacket, face shield, goggles, and rubber

gloves. Use proper lifting techniques.

20


Date: 9/12/92Revised: 7/18/97

Written By: Kent AndersonReviewed By: MEB


Task: Bypass Dilution Tank.

Work Step Potential Hazards Corrective Action1. Open dilution tank bypass valve. Acid burns, cuts on rough valves. Wear acid jacket, face shield, goggles, and gloves.2. Close dilution tank inlet valve from plants and

make sure recycle valve is open.Same as one. Same as one.

3. Close outlet valve on dilution product line totank farm.

Same as one. Same as one.

4. When everyone is clear of the dilution tank,call the chief, to shut down the dilution acidpump.

None. None.

21


Date: 2/11/90Revised: 7/1/97

Written By: C- ShiftReviewed By: MEB


Task: Valve in boiler sight glasses.

Work Step Potential Hazards Corrective Action1. Place safety chain back on sight glass. Steam/or Hot water. Thermal burns. Wear gloves.2. Close drains on bottom of sight glasses and

water column.Same as one. Same as one.

3. Unlock steam and water valve. Same as one. Same as one.4. Open bottom valve from boiler slowly. Same as one. Same as one.5. Open top valve from boiler slowly. Same as one. Same as one.

22


Date: 2/11/90Revised: 7/2/97

Written By: C-ShiftReviewed By: MEB


Task: Valve out boiler sight glasses.

Work Step Potential Hazards Corrective Action1. Close top steam valve from boiler to water

column.Steam and or hot water. Thermal burns. Wear gloves.

2. Close bottom water valve from boiler to watercolumn.


3. Open drains on bottom of water column andsight glass.


4. Lock out steam and water valves. Same as one. Same as one.5. Remove safety chain if necessary.. Same as one. Same as one.

23



Written By: Willie EdwardsReviewed By: MEB


Task: Blow boilers down manually.

Work Step Potential Hazards Corrective Action1. Clear personnel from area of blow down pot. None. None.2. Open one blow down block valve on boiler. Rough valve handle, steam leak, thermal burns. Wear gloves.3. Open main header block valve for

approximately 15 sec..Same as one. Same as one.

4. Close main header block valve. Same as one. Same as one.5. Close blow down block valve on boiler. Same as one. Same as one.6. Repeat steps 2-5 for the remaining 3 blow

down block valves.Same as one. Same as one.

24



Written By: Ron PierceReviewed By: MEB


Task: Depressure and drain boilers.

Work Step Potential Hazards Corrective Action1. After plant is shut down. Close both block

valves on steam drum.Hand injuries. Wear leather gloves.

2. Start manually blowing down boilerscontinuously controlling with outside blowdown valve.

Hand injuries. Wear leather gloves.

3. When pressure gets down to 100lbs.. Startadding well water through well water line.Open drain to ditch.


4. When pressure reaches 25lbs. Open vent ontop of steam drum.

Hot water and steam shooting out of vent, thermalburns.

Wear acid jacket, face shield, and leather gloves.

5. When pressure reaches 0lbs. Discontinue wellwater and let boilers drain through open drainvalves.


25


Date: 9/14/92Revised: 7/2/97

Written By: C. WalkerReviewed By: MEB


Task: Check boiler level trip(plant shutdown)

Work Step Potential Hazards Corrective Action1. Slow blower to 10”. Clear furnace of sulfur. Thermal burns. Wear gloves.2. Close bottom valve to Eye- Hye , and open

Eye-Hye drain valve.Thermal burns. Wear gloves.

3. Confirm that blower tripped. Thermal burns. Wear gloves.4. Close Eye-Hye drain valve, and open bottom

valve to Eye-Hye.Thermal burns. Wear gloves.

26



Written By: D-shiftReviewed By: MEB


Task: Put OA Superheater in service.

Work Step Potential Hazards Corrective Action1. Before plant is heated up OA inlet, outlet, and

automatic valves are closed, and drain andvent valves are opened.

Burrs on valve handles, Hand injuries. Thermalburns.

Wear gloves.

2. Before putting plant on sulfur. Close drainvalves, and check that valves are open to traps.

Burrs on valve handles, Hand injuries . Thermalburns.

Wear gloves.

3. Slowly open outlet block valves until OAstarts to pressurize. Close vent valves when airis purged from OA.

Burrs on valve handles, Hand injuries, Thermalburns.

Wear gloves.

4. When OA is pressurized, open outlet valve100% . Leave automatic valve in manual andclosed until, after plant is on sulfur.

Burrs on valve handles, Hand injuries, Thermalburns.

Wear gloves.

5. Open inlet block valve 100%. Burrs on valve handles, Hand injuries, Thermalburns.

Wear gloves.

6. Check that traps are working. Burrs on valve handles , Hand injuries, Thermalburns.

Wear gloves.

27



Written By: A-shiftReviewed By: MEB


Task: Put 4A Superheater in service.

Work Step Potential Hazards Corrective Action1. Before(plant heat up) close inlet manual valve.

Open outlet valve. Close automatic valve.Burrs on valve handles, hand injuries. Wear gloves.

2. Open vents and drains valves on 4ASuperheater.

Burrs on valve handles, hand injuries. Wear gloves.

3. Check that the battery limits Superheatedsteam valve remains closed.

Burrs on valve handles, hand injuries, thermalburns.

Wear gloves.

4. During heat when 4th pass outlet temp reaches475 deg. Close drains and vents on 4A andsuperheated steam line. Open superheatedsteam valve at battery limits.

Burrs on valve handles, hand injuries, steam andhot water, thermal burns.

Wear gloves.

5. Before plant goes on sulfur open manual inletvalve, Automatic valve stays closed until plantgoes on sulfur.

Burrs on valve handles, hand injuries, steam andhot water, thermal burns.

Wear gloves.

28


Date: 5/14/89Revised: 7/1/97

Written By: T. McBrideReviewed By: MEB


Task: Depressurize Superheater.

Work Step Potential Hazards Corrective Action1. After plant is down and secured. Close inlet

and exit manual steam valves.Thermal burns, high pressure steam, rough valvehandles.

Wear gloves, avoid leaks and hot surfaces.

2. Open vents. Same as one. Same as one.3. Open drains on steam traps and superheater. Same as one. Same as one.

29


Date: 3/26/90Revised: 7/2/97

Written By: A-shiftReviewed By: MEB


Task: Back Saturated Steam into plant.

Work Step Potential Hazards Corrective Action1. Partially open condensate drain valves in

plant.Thermal burns from hot water and steam. Wear gloves. Stand to one side when opening drain

valves.2. Partially open 600lb. Saturated Steam valve to

plant.Climbing, Hand injuries, thermal burns, waterhammer.

Maintain three point stance. Wear gloves, Openvalve slowly.

3. Close drain valves when only steam is comingout.


4. After Saturated Steam header is pressurizedslowly open Saturated Steam valve to 100%.

Same as two. Same as two.

30


Date: 2/10/90Revised: 7/2/97

Written By: C-shiftReviewed By: MEB


Task: Put Flash Tank in Service.

Work Step Potential Hazards Corrective Action1. Open valves to level control valve. Hand injuries. Wear gloves.2. Open steam valve to feedwater heater. Hand injuries. Wear gloves.3. Open flash tank inlet block valve. Hand injuries. Wear gloves.4. Open blowdown block valve to flash tank. Hand injuries. Wear gloves.5. Close blowdown valve on line to atmosphere. Hand injuries. Wear gloves.

31


Date: 5/14/89Revised: 7/2/97



Task: Drain Economizers.

Work Step Potential Hazards Corrective Action1. Shut down feedwater pump to plant. None. None .2. Close inlet and outlet valves to section to be

drained.Rough valve handles, hand injuries, thermal burns. Wear gloves.

3. Open drains, and vent valves. Same as two. Place board under drain so a large hole is not dug inground or asphalt. Open valves slowly, standing toone side. Wear gloves.

32


Date: 3/28/91Revised: 7/7/97

Written By: J. RagoonananReviewed By: MEB


Task: Start up Keystone boiler.

Work Step Potential Hazards Corrective Action1. Open feedwater valves to boiler. Bring boiler

water level to operating level.Over filling boiler, may put water in steam linescausing a water hammer. Rough valve handles.

Monitor water level while filling boiler. Weargloves.

2. Open steam drum block valve. Relief valve may open If boiler over pressures, dueto steam drum block valve being closed.

Make sure block valve is open.

3. Start forced draft fan. None. None.4. Start #2 fuel oil supply pump. Fuel oil leaking into boiler. Make sure oil supply valves are closed.5. Open atomizing steam, oil, and LP gas valve. Oil or steam leaks, hand injuries. Wear gloves.6. Start ignition sequence. Explosion. Stand clear of burner until after ignition.7. Adjust air/fuel ratio to assure a clear stack. Air pollution. Maintain air ratio at least 10% higher than fuel .8. When pressure reaches 25# close steam vent. Hot water, steam blowing out vent, thermal burns. Wear gloves.

33


Date: 7/16/89Revised: 7/8/97

Written By: R. RiceReviewed By: MEB


Task: Run Sulfur Gun survey.

Work Step Potential Hazards Corrective Action1. Shut off #1 sulfur gun. Burns from sulfur or steam. Wear face shield, acid jacket, and gloves.2. Put #1 gun on when call received from chief. Same as 1. Same as 1.3. Repeat steps 1 and 2 with other four sulfur

guns.Same as 1. Same as 1.

4. * Note: Wear green welders coat instead of acidjacket.

34





Task: Valve out steam on sulfur guns.

Work Step Potential Hazards Corrective Action1. Check that sulfur gun cooling steam drain

lines are open.Explosion. If both inlet and outlet steam lines areblocked. Pressure could build up in guns. Thermalburns.

Wear gloves. Make sure drains are not plugged.

2. Close sulfur gun inlet cooling steam valve. Thermal burns. Wear gloves, and avoid contact with hot steamlines.

3. *Note: Wear green welders jacket on sulfurplatform.

35


Date: 5/13/89Revised: 7/8/97

Written By: S. HenryReviewed By: MEB


Task: Unplugging Sulfur Guns.

Work Step Potential Hazards Corrective Action1. Check to make sure gun and sulfur lines are

hot.Hot steam and hot sulfur. Wear face shield, acid jacket, and leather gloves.

2. Check condensate drain. Same as 1. Same as 1.3. Close and open sulfur valve to gun. Same as 1. Same as 1.4. *Note: Wear green welders jacket instead of acid

jacket.

36


Date: 3/26/90Revised: 7/8/97

Written By: A shiftReviewed By: MEB


Task: Put Sulfur Gun in service.

Work Step Potential Hazards Corrective Action1. Make sure cooling steam is on sulfur guns. Thermal burns. Wear welders jacket, face shield, and leather

gloves.2. Check that sulfur guns and lines are hot

enough to melt sulfur.Thermal burns. Same as 1.

3. Open valve to sulfur gun. Sulfur leaks thermal burns. Same as 1.4. Verify sulfur flow and spray pattern. Thermal burns. Same as 1.

37


Date: 5/22/89Revised: 7/10/97

Written By: J. RagoonananReviewed By: MEB


Task: Put Steam on Sulfur Guns.

Work Step Potential Hazards Corrective Action1. Make sure sulfur gun drain is open. Thermal burns. Wear green welders jacket, face shield, and gloves.2. Slowly open supply steam valve to sulfur gun. Thermal burns. Same as 1.

38


Date: 6/3/89Revised: 7/10/97

Written By: HolcombReviewed By: MEB


Task: Start Oil Fire.

Work Step Potential Hazards Corrective Action1. Check that dampers and start up stack are set

up for oil fire.None. None.

2. Start air compressor and open air valve to oilgun.

Air leaks. Make sure hose connections are tight and pinned.

3. Start #2 fuel oil pump. Oil leaks. Shut oil pump down.4. Slow roll blower, and purge furnace. High volume of air blowing from start up stack and

boiler manways.Barricade area at boiler manways.

5. Stick torch in bucket of #2 fuel oil andremove.

Spill fuel oil. Bucket should set flat on surface.

6. Light torch. Thermal burns. Wear face shield and gloves, green welders jacket.Keep safe distance from lit end of torch.

7. Insert torch in burner below oil gun. Soot and smoke could blow back. Wear face shield and gloves. Keep distance fromhole.

8. Open oil valve to gun. Fuel oil leaks. Shut off oil and repair leaks.9. After oil gun lights off, remove torch. Thermal burns. Same as 6.10. Put torch in bucket of #2 fuel oil to put out

fire.Thermal burns. Stick lit end of torch directly into fuel oil bucket.

Fuel oil should be deep enough to cover entireflame at once.

11. Adjust fuel oil valve to gun according totemperature.

Thermal burns. Wear gloves.

39


Date: 6/3/89Revised: 7/10/97



Task: Watch Oil Fire on heat up.

Work Step Potential Hazards Corrective Action1. Watch oil fire. Fire going out and oil collecting in bottom of

furnace.Shut off oil gun.

2. *Note: Wear green welders jacket.

40


Date: 2/11/90Revised: 7/1/97

Written By: C shiftReviewed By: MEB


Task: Change oil tip during oil fire heat up.

Work Step Potential Hazards Corrective Action1. Shut off #2 fuel oil pump. None. None.2. Shut off oil valve to gun. Hand injuries. Wear gloves.3. Purge gun and shut off air valve to gun. Same as 2. Same as 2.4. Shut down blower. Same as 2. Same as 2.5. Remove gun from burner. Thermal burns and hand injuries. Same as 2.6. Remove and replace oil gun tip. Same as 5. Same as 2.7. Return gun to furnace. Same as 5. Same as 2.8. Turn atomizing air on. Same as 2. Same as 2.

41


Date: 2/11/93Revised: 7/10/97

Written By: C shiftReviewed By: MEB


Task: Changing fuel oil filters during oil fire heat up.

Work Step Potential Hazards Corrective Action1. Shut off #2 fuel oil pump. None. None.2. Close valves on inlet and outlet of filters. Hand injury(rough valves)l Wear gloves.3. Open filter drain valves. Oil spray, hand injury. Stand clear , wear gloves.4. Change filters. Handling oily filters. Same as 2.5. Close drain valves. Same as 2. Same as 2.6. Start fuel oil pump. Same as 2. Same as 2.7. Check for leaks. Same as 3. Same as 3.8. * Note: Wear green welders jacket while on sulfur

platform.

42


Date: 6/1/89Revised: 7/10/97

Written By: G. LondonReviewed By: MEB


Task: Adjust plant dampers.

Work Step Potential Hazards Corrective Action1. Adjust chain operated damper. Falling gear operator. Falling rust. Make sure safety cable is attached to gear operator.

Wear safety glasses.2. Open or close boiler exit and bypass dampers

as directed by chief.Closing both dampers on one boiler will smotherthe fire in the furnace. Reopening one of thedampers will cause a sulfur explosion.

At no time while the plant is on sulfur should the#1 or #2 boiler exit and bypass dampers be closedat the same time. Always open one damper 100%before closing the other.

43


Date: 5/14/89Revised: 7/10/97

Written By: Kent AndersonReviewed By: MEB


Task: Obtain Plant Readings.

Work Step Potential Hazards Corrective Action1. Walk through plant and obtain readings. Acid burns, thermal burns, and gas fumes. Look for leaks in area and report.

44


Date: 8/23/90Revised: 7/10/97



Task: Checking Stack Drain.

Work Step Potential Hazards Corrective Action1. Go on final pump tank. Chemical burns. Wear face shield, goggles, acid suit, and rubber

gloves.2. Close stack drain valve to pump tank. Chemical burns, hand injuries. Same as 1.3. Open air valve and check pressure gauge. Same as 2. Same as 1.4. Close air valve and open drain valve. Same as 2. Same as 1.

45


Date: 5/1/90Revised: 7/10/97

Written By: Ron PierceReviewed By: MEB


Task: Check moisture drains, Boilers and economizers.

Work Step Potential Hazards Corrective Action1. Open drain slowly. Splash from hot low PH solution. S02 and S03 gas. Wear acid jacket, face shield, goggles, and gloves.

Stand up wind.2. Check for moisture. Same as 1. Same as 1.3. Close drain. Same as 1. Same as 1.

46


Date: 6/1/89Revised: 7/10/97



Task: Barricade acid leaks.

Work Step Potential Hazards Corrective Action1. Rope off area with red barricade tape. Chemical burns. Wear face shield, goggles, acid suit, and gloves.

47


Date: 5/13/89Revised: 7/10/97



Task: Caustic Wash Main Compressor.

Work Step Potential Hazards Corrective Action1. Shut down compressor. Thermal burns. Wear gloves.2. Have maintenance open manway on suction

duct.None. None.

3. Connect water and steam hoses to compressordrain pipe.


4. Open valve from stand pipe to blower drainline and pour 5 gallons of caustic intocompressor.

Chemical burns. Wear face shield, goggles, acid suit, and rubbergloves.

5. Close valve from stand pipe. Open valve fromwater hose to drain pipe, and fill compressorpart way with water.

Chemical burns. Same as 3.

6. Open valve from steam hose to compressordrain line.

Thermal burns, hose rupture. Wear gloves. Inspect hose for wear. Make suresafety pins are used.

7. Slow roll compressor. Thermal burns, chemical burns. Caustic solutionsplashing out of manway.

Wear face shield, goggles, acid suit, and gloves.Barricade area around manway.

48


Date: 7/21/89Revised: 7/10/97

Written By: B. EnglishReviewed By: MEB


Task: Shut down Main Blower.

Work Step Potential Hazards Corrective Action1. Make sure that auxiliary lube oil pump comes

on.None. None.

2. Close trip and throttle valve slowly. Thermal burns and noise. Wear gloves, wear hearing protection.3. Close slide gate damper. Possible S02 release. Close slide gate before compressor stops roll to

prevent possible S02 release.

49


Date: 12/25/92Revised: 7/10/97



Task: Start up Main Blower.

Work Step Potential Hazards Corrective Action1. Open drains on steam trap to 575# and 45#

steam lines to turbine.Thermal burns, and hand injuries. Wear gloves.

2. Close valve to 45# vent. Same as 1. Same as 1.3. Open 45# steam exhaust valve. Same as 1. Same as 1.4. Open 575# steam inlet valve to trip and

throttle valve.Same as 1. Same as 1.

5. When steam is dry and hot, close drain valveson steam traps.

Same as 1. Same as 1.

6. Turn on auxiliary oil pump. Check oil pressureand level in reservoir.

None. None.

7. Check oil in governor. None. None.8. Open trip and throttle valve an slow roll

turbine for 30min.. If coming off turn around.If down for 1 hour or more slow roll for20min..


50


Date: 1/12/90Revised: 7/14/97

Written By: GGRReviewed By: MEB


Task: Start up #6 Fuel Oil Dispensing Pump.

Work Step Potential Hazards Corrective Action1. Open inlet and discharge valves on pump. Hand injuries . Wear gloves.2. Start pump. Oil leaks. Shut off pump.

51


Date: 9/14/92Revised: 7/14/97

Written By: Oliver Jennings.Reviewed By: MEB


Task: Start #2 Fuel Oil Pump.

Work Step Potential Hazards Corrective Action1. Open inlet and discharge valves on pump. Hand injuries. Wear gloves.2. Start pump. Fuel oil leaks. Shut down pump.

52


Date: 2/12/90Revised: 7/14/97



Task: Start Up Well Water Pumps.

Work Step Potential Hazards Corrective Action1. Open inlet valve. Hand injuries. Wear gloves.2. Open discharge valve to 25% open. Same as 1. Same as 1.3. Start pump. None. None.4. After line is up to pressure, open discharge

valve 100%Same as 1. Same as 1.

53


Date: 7/14/97Revised:

Written By: K. EldridgeReviewed By: MEB


Task: Bleach Cooling Tower.

Work Step Potential Hazards Corrective Action1. Open inlet and outlet valves to bleach pump. Chemical burns. Wear face shield, and rubber gloves.2. Turn on bleach pump and let run for

designated time.Bleach leaks. Turn pump off.

3. Shut off bleach pump. None. None.4. Close inlet and outlet valves to bleach pump. Chemical burns. Wear face shield, and rubber gloves.

54


Date: 2/12/90Revised: 7/14/97



Task: Bypass Feedwater Heater.

Work Step Potential Hazards Corrective Action1. Open continuous blowdown valves to

atmosphere, and close valves to flash tank.Thermal burns. Hand injuries. Wear gloves.

2. Close 5# steam valve and 5# bypass valve tofeedwater heater.


3. Close boiler feedwater heater recycle valves ateach boiler feedwater pump.


4. Close condensate return lines to feedwaterheater.


5. Open feedwater heater bypass valve. Same as 1. Same as 1.6. Close feedwater heater main discharge valve. Same as 1. Same as 1.7. Close feedwater heater inlet water valve. Same as 1. Same as 1.

55


Date: 6/6/89Revised: 7/17/97

Written By: G. NicholsReviewed By: MEB


Task: Start up Boiler Feedwater Pump.

Work Step Potential Hazards Corrective Action1. Valve in lubricating oil lines. None. None.2. Start lubricating oil pump and check oil flow

to bearings.None. None.

3. Close drain valves on pump. Thermal burns, Hot water. Wear gloves.4. Open air bleed valves on pump. Thermal burns, Hot water. Wear gloves.5. Open inlet and outlet water valves to pump.

When water comes out of air bleed valvesclose valve back to allow a low flow frompump until pump heats up.

Thermal burns, Hot water. Wear gloves.

6. When pump is hot shut off air bleeds. Thermal burns. Wear gloves.7. Valve in cooling water to pump. Burrs on valve wheel. Wear gloves.8. Open recirculation valve. Thermal burns. Wear gloves.9. Start pump. Hot water leaks. Stand clear of pump.

56


Date: 6/3/89Revised: 7/17/97



Task: Charge Chemical Day Tanks.

Work Step Potential Hazards Corrective Action1. Drain chemicals from bulk tank to measuring

bucket.Chemical burns. Wear acid jacket, face shield , goggles, and rubber

gloves.2. Pour chemicals from bucket to day tank. Same as 1. Same as 1.3. Fill tank with water. Same as 1. Same as 1.

57


Date: 6/17/93Revised: 7/17/97



Task: Start up Cold well Pumps.

Work Step Potential Hazards Corrective Action1. Open discharge valve 25%. Burrs on valve handle. Slippery footing. Wear gloves and watch footing.2. Open air bleed valve. None. None.3. Start pump. Same as 2. Same as 2.4. Close air bleed valve. Same as 2. Same as 2.5. Open discharge valve 100%. Same as 2. Same as 2.

58


Date: 6/3/89Revised: 7/17/97



Task: Run Water Samples in Lab.

Work Step Potential Hazards Corrective Action1. Inspect all glassware for chips or cracks. Cuts to hands. Discard all faulty glassware.2. Run samples per test procedures. Splash chemicals in eyes. Wear safety glasses.

59


Date: 5/22/89Revised: 7/17/97

Written By: S. HenryReviewed By: MEB


Task: Establish Chlorination to Potable Water.

Work Step Potential Hazards Corrective Action1. Open water valve to ejector. And check

vacuum.None. None.

2. Crack open discharge valve on cylinder andestablish flow.

Chlorine leak. Wear rubber gloves, acid jacket, and full facerespirator.

3. Open discharge valve on cylinder 100% andadjust set point to get desired residual.


4. Open discharge valve on standby cylinder. Same as 1. Same as 1.

60


Date: 6/1/89Revised: 7/21/97

Written By: G. HolcombReviewed By: MEB


Task: Start up Diesel Deep Well Pump.

Work Step Potential Hazards Corrective Action1. Shut down south deep well and lock out

motor.None. None.

2. Have maintenance connect shaft to diesel, asper written procedure posted at the pump.

None. None.

3. Check fuel and oil levels. None. None.4. Check coupling guard. None. None.5. Valve in cooling water. Burrs on valve wheel. Wear gloves.6. Push start button for diesel. Mechanical failure. Stand clear of unit.7. Adjust diesel to desired RPM. High noise level. Wear hearing protection.

61


Date: 6/1/89Revised: 7/21/97



Task: Start up Cooling Tower Fans.

Work Step Potential Hazards Corrective Action1. Climb stairs to top of cooling tower. Stairs could be wet and slippery. Use hand rails and take one step at a time.2. Check oil level sight glass and coupling guard. None. None.3. Push start button. Electrical shock. Fan coming apart. Check for bare wires. If fan has unusual noise or

vibration shut fan down.

62


Date: 5/13/89Revised: 7/21/97

Written By: JAWReviewed By: MEB


Task: Start up Potable Water Pumps.

Work Step Potential Hazards Corrective Action1. Open inlet water valve. Hand injuries. Wear gloves.2. Open discharge valve partially. Same as 1. Same as 1.3. Start pump. None. None.4. Open discharge valve 100%. Same as 1. Same as 1.5. Open inlet and outlet valves to standby pump. Same as 1. Same as 1.6. Turn standby pump switch to automatic. None. None.

63


Date: 9/14/92Revised: 7/21/97

Written By: M. AdamsReviewed By: MEB


Task: Start up Electric Deep Well Pumps.

Work Step Potential Hazards Corrective Action1. Open discharge valve to 100%. Hand injuries. Wear gloves.2. Check that check valve is working. Coupling or pump failure when pump is started. Close discharge valve and repair check valve.3. Push start button. Blast of air from pump vacuum break vent. Stand clear of vacuum break.

64


Date: 0/14/92Revised: 2/9/93

Written By: C WalkerReviewed By: MEB


Task: Put Feed Water Heater in service.

Work Step Potential Hazards Corrective Action1. Go to feed water heater platform, close drain

valve.Tripping hazards. Keep stairway clear of debris.

2. Open block valves to level control 100%. Hand injuries. Wear gloves.3. Open valve at bottom of feedwater heater to

suction of pumps 100%.Hand injuries, rust falling from chain operator. Wear gloves , wear goggles.

4. Start treated water pump. None. None.5. Have chief open auto level control valve and

fill feed water heater to proper level.None. None.

6. Valve in 5# steam valve to feed water heater. Thermal burns, hand injuries. Wear gloves.

65


Date: 9/13/92Revised: 7/21/97

Written By: Kent AndersonReviewed By:


Task: Clean Cooling Tower Screens.

Work Step Potential Hazards Corrective Action1. Pull up grating and place it to one side. Hand injuries and back strain. Wear gloves , bend knees when lifting.2. Attach hoist to lifting bolts on screen. None. None.3. Raise up screen with hoist. Falling load. Inspect lifting equipment. Stand clear of load.4. Move screen to side of sump and wash it with

water.Same as 3. Same as 3.

5. Move screen to sump and lower it intoposition with hoist.


6. Put grating back over the screen. Same as 1. Same as 1.

66


Date: 9/14/92Revised: 7/21/97

Written By: C. WalkerReviewed By: MEB


Task: Put Fin/ Fan Condenser in Service.

Work Step Potential Hazards Corrective Action1. Valve in condensate pumps, and turn switches

to auto.Hand injuries. Thermal burns. Wear gloves.

2. Open valve to automatic steam valve. Same as 1. Same as 1.3. Put switches to fans in auto. None. None.

67


Date: 9/14/92Revised: 7/21/97

Written By: M. AdamsReviewed By: MEB


Task: Obtain Boiler Water Samples.

Work Step Potential Hazards Corrective Action1. Open drain valve on sample port. Hot water and steam thermal burns. Wear rubber gloves.2. Rinse bottle with sample water. Same as 1. Same as 1.3. Catch sample and replace lid on sample bottle. Same as 1. Same as 1.4. Close sample valve. Same as 1. Same as 1.

68


Date: 2/12/90Revised: 7/22/97



Task: Dip Acid Storage Tanks.

Work Step Potential Hazards Corrective Action1. Drop float into tank until it touches acid level. Cuts from tape. Wear rubber gloves.2. Check measurement on tape. Same as 1. Same as 1.3. Retrieve float. Cuts from tape. Also possibly acid on tape and

float.Wear rubber gloves, rinse tape and float thoroughlywith water.

69


Date: 8/10/89Revised: 7/21/97

Written By: Walker/ BussellReviewed By: MEB


Task: Sulfuric Storage Tanks: Cleaning procedures.

Work Step Potential Hazards Corrective Action1. Check to make sure JSA for securing tank has

been followed.Acid leaks. Be alert for leaks. Locate safety showers.

2. Position attendant outside of tank to beentered, with a ¾ water hose running,

Hose failure. Check hose connections.

3. Obtain temperature reading inside of tankfrom manway.

Acid inside tank. Wear acid jacket, face shield, goggles, rubber bootsand gloves, while obtaining temperture frommanway.

4. If temperature is 95 deg. F. or less, enter tankand run a sniff test. If above 95 Deg F. contactsupervision.

Acid inside tank. Heat and fumes. Slippery floor. Wear full acid suit, face shield, goggles, rubbergloves and boots. Respirators must also be worn becareful when walking across tank.

5. Using squeegees, remove remaining acid fromthe tank floor.


6. Add soda ash to tank. Same as 3. Same as 3.7. Wash out tank with fire loop water. Same as 3, and fire hose rupture. Same as 3, also check hose connections.8. Squeegee tank floor and wipe. Same as 3. Same as 3.

70


Date: 8/10/89Revised: 7/22/97

Written By: Walker/BussellReviewed By: MEB


Task: Prepare Sulfuric Acid Tank for Service After Cleaning.

Work Step Potential Hazards Corrective Action1. Close drain valve from tank to ditch and blank

off.Burrs on valve handle. Wear gloves.

2. Bolt manway back on side of tank. Weight of manway cover. Use crane or boom truck.3. Remove fan and bolt down manway on top of

tank.Weight of fan and cover. Use crane. Wear safety harness.

4. remove blanks from fill lines and replace spoolpieces, and 90’s or 45’s that were removed tosecure tank.

Acid in lines. Wear full acid suit, face shield, goggles, rubbergloves and boots.

5.6.7.8. Remove blanks from suction lines to transfer

pumps, and replace spool piece, that wasremoved to secure tank.


9. Check level in adjacent tanks to be sure theyare well below overflow lines. Remove blanksin overflow lines and replace spool piece or 90that was removed to secure tank.


10. Remove locks and tags from fill valves andtank discharge valves. To transfer pumps.

Burrs. Wear gloves.

71


Date: 5/22/89Revised: 7/22/97



Task: Switching Acid Storage Tanks.

Work Step Potential Hazards Corrective Action1. Open fill valves to tank being switched to. Acid burns. Wear acid jacket, face shield, goggles, and rubber

gloves.2. Close fill valves on tank being switched from. Same as 1. Same as 1.

72



Written By: HolcombReviewed By: MEB


Task: Start Up Acid Transfer to Phos-Acid.

Work Step Potential Hazards Corrective Action1. Open suction valve on transfer pump. Acid leak. Burrs on valve handle. Wear acid suit. Face shield, goggles, and rubber

gloves.2. Open discharge valve on tank. Same as 1. Same as 1.3. Open discharge valve on pump 25%. Same as 1. Same as 1.4. Contact Phos-Acid chief by radio. None. None.5. Start transfer pump. Acid leak. Same as 1.6. Open discharge on pump 100%. Same as 1. Same as 1.

73


Date: 6/3/89Revised: 7/25/97

Written By: A. TaylorReviewed By: MEB


Task: Start up Air Compressors.

Work Step Potential Hazards Corrective Action1. Open cooling water valves. Slipping, hand injuries, air leaks. Have sure footing. Wear gloves.2. Push start switch. None. None.

74


Date: 6/1/89Revised: 7/10/97

Written By: K. TaylorReviewed By: MEB


Task: Dip Sulfur Tanks.

Work Step Potential Hazards Corrective Action1. Climb stairs to top of sulfur tank. Slipping and falling. Use hand rails.2. Obtain tank dip by lowering measuring tape

through hole in top of sulfur tank, until floatreaches sulfur level. Read measurement ontank.

Thermal burns. Cut from measuring tape. Wear gloves.

75


Date: 6/5/86Revised: 7/14/97

Written By: Rice/HerbolsheimerReviewed By: MEB


Task: Start Up Sulfur Pumps.

Work Step Potential Hazards Corrective Action

1. Make sure steam traps are working and sulfurpump and lines are hot.


2. Start pump. Thermal burns. Sulfur leaks. Wear acid jacket, face shield, goggles and gloves.3. Contact chief by radio. Open discharge valve. Same as 2. Same as 2.

76


Date: 2/4/90Revised: 7/14/97



Task: Dipping Tank Pit.

Work Step Potential Hazards Corrective Action1. Remove sulfur from rod. Thermal burns. Wear gloves.2. Place rod in dip hole until it touches bottom of

pit.Same as 1. Same as 1.

3. Take rod out of pit and place againstmeasuring tape.


77


Date: 7/24/89Revised: 7/25/97

Written By: R. ThompsonReviewed By: MEB


Task: Lock Out Breaker in MCC.

Work Step Potential Hazards Corrective Action1. Make sure equipment for breaker is down. None. None.2. Push the lever down de-energizing breaker. Explosion. Stand to one side.3. Put a lock and tag on breaker. None. None.4. Test field switch to see is equipment starts. Equipment starting. Check breaker . Call electrician.

78


Date: 8/10/89Revised: 7/22/97

Written By: Walker/BussellReviewed By: MEB


Task: Secure Acid Tank For cleaning.

Work Step Potential Hazards Corrective Action1. Close lock out and tag both product acid

valves to tank.Acid leaks. Wear full acid suit, face shield goggles and rubber

gloves.2. Close lock out and tag fill valves from truck

unloading stations. Remove unloading hoses.Same as 1. Same as 1.

3. Pump out tank as low as possible usingtransfer pump.


4. Stop transfer pump. Same as 1. Same as 1.5. Close lock out and tag transfer pump suction

valve and adjacent tank isolation valve.Same as 1. Same as 1.

6. Remove blank from drain line and install aciddrain pump at drain valve.


7. Install drain hose from drain pump to anotheracid tank.


8. Pump out tank as much as possible with drainpump.

Acid leaks, Hose rupture. Wear full acid suit , face shield, goggles andrubber gloves. Check hose and connectionscarefully. Watchman MUST be present any timedrain pump is running.

9. Stop drain pump. Close drain valve. Same as 1. Same as 1.10. Disconnect all hoses to and from drain pump

and remove pump.Acid in hoses. Same as 1.

11. Open drain valve from tank to ditch. Acid in drain line. Same as 1.12. Remove spool piece, 90 or 45, between fill

valves and tank. Install blank on fill line.Acid in lines. Same as 1.

13. Remove spool piece between tank and transfer Acid in lines. Same as 1.

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pump suction. Install blank on pump suctionline.

14. Check that acid levels in adjacent tanks arewell below over flows. Remove spool piece, or90 in over flow lines and blank over flow linesfrom adjacent tanks.

Acid in lines. Same as 1.

15. Open manway on tank. Acid in tank. Weight of manway. Same as 1. Use crane or boom truck.16. Open manway on top of tank. Weight of manway cover. Use crane. Wear safety belt.17. Install fan on top manway. Weight of fan. Same as 16.

TASK: OPEN/CLOSE PRODUCT ACID VALVE 5 … TASK: START UP SULFUR PUMPS ... 5 Job Safety Analysis...

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Transcript of TASK: OPEN/CLOSE PRODUCT ACID VALVE 5 … TASK: START UP SULFUR PUMPS ... 5 Job Safety Analysis...