Site Specific Rules at Plants. Individual Unit Function: Safety Procedure No.: SOP-0135 Page: 1 of 8

Transcription

1 Procedure No.: SOP-0135 Page: 1 of 8 Preparer: Owner: Approver: Safety Safety Safety 1. PURPOSE To provide BASF site specific rules for the protection of all MIDGA and contract personnel. These rules will provide for the protection of all employees while at specific plant sites. 2. DEFINITIONS 3. SCOPE All MIDGA employees and contractor employees. 4. PROCEDURE Gordon Plant Purpose: This procedure is designed to protect all of MIDGA s shipping personnel and Norfolk Southern from injury associated with the routine rail car switching activities while in the Gordon Plant area. The proper and consistent use of this procedure is mandatory, and its importance is equivalent to our lock-tag-try procedure. Procedure: Whenever Norfolk Southern is conducting switching activities in the Gordon Plant, the following procedures will be in place. GENERAL INFORMATION Some railroad tracks in the Gordon Plant will be grouped into pairs based upon their closeness to one another. Each track in a pair share a common switch where a single track diverges into the two tracks in the pair. Track Pairs: Track 9 & 6 Track 7A & 7B Track 3 & 4 Track 1 & 2 (Tracks in Columbia Plant) Track 1 & 2 (Tracks in Savannah Plant)

2 Procedure No.: SOP-0135 Page: 2 of 8 Tracks 5, 7, and 8 do not require pairing POSITIVE PROTECTION FROM NORFOLK SOUTHERN SWITCHING Protection from Norfolk Southern switching will be provided by permanent lockable derails (with blue flags). The derail between all the Gordon Plant railroad tracks branches and the mainline (Norfolk Southern) track will be activated and locked out when no switching is occurring. When the Norfolk Southern switch engine arrives at the plant to commence switching, which occurs about 6:30a.m. each day, the lock will be removed by a designated BASF employee and the derail deactivated. When switching operations are completed, the Car Leader Man will be responsible for reactivating and locking the derail. This will ensure that at least one person in the Gordon Plant is aware of when switching starts and ends. Permanent derails with blue flags will be placed north of (on the mainline track side) the common (shared) switches for each pair of tracks (9/6, 3/4, 1/2 Columbia Plant, and 1/2 Savannah Plant). A permanent derail with a blue flag will be placed approximately 100 feet north of the shared switch of tracks 7A/7B on track 7. Permanent derails with blue flags will be placed on the non-paired tracks (5, 7 and 8) near where each of these tracks diverge from another track. (See attached layout drawing for a location of derails). 1. For car loading personnel, protection during car switching will be provided by the following: For Tracks Grouped in Pairs/Gordon Location The derail located above each common switch will (already) be activated (in its up position and locked) by the Car Leader Man to protect both tracks (in the pair) before the start of car switching. The loading foreman (or designee) in a particular area will know if work is being performed on any of the tracks. a. If switching cannot be safely performed on either of the tracks (in the pair), the derail will remain activated and locked. b. If switching can be safely performed on both tracks (in the pair), the derail will be unlocked and deactivated by the Car Leader Man. The Car Leader Man in each plant area will be responsible for reactivating and relocking the derail after the Norfolk Southern crew has completed switching for the day. c. If switching can safely occur on only one track in the pair, the derail will be unlocked, deactivated and the common (shared) switch will be locked by the Car

3 Procedure No.: SOP-0135 Page: 3 of 8 Leader Man in one direction to protect the proper track in the pair (but allow the other track to have movement taking place on it). The Car Leade Mman in each plant area will be responsible for unlocking the switch and reactivating and relocking the derail after the Norfolk Southern crew has completed switching for the day. a. For Tracks Not Grouped in Pairs (Tracks 5, 7, and 8) b. The derail located on each of these tracks will (already) be activated (locked into its up position) to protect the track at the start of the car switching process. Area loading foreman (or designee) will monitor the loading areas for work being performed on tracks. c. If switching cannot be safely performed on the track, the derail will remain activated and locked. d. If switching can safely occur on the track, the derail will be unlocked and deactivated by the Car Leader man before switching and the derail will be activated and locked by the Car Leader Man after switching. Loading foreman (or designee) coming to work should verify the status of derails at the start of their shifts. 1. For maintenance, new construction or outside services personnel working on a track. Protection during car movement will be provided by the following: For Tracks Grouped In Pairs a. The construction supervisor will attach his safety lock to the already activated derail (which has a Car Leader Man lock on it) before starting any work on a track. If the derail is not already activated and locked, he should find out why. b. If switching cannot be safely performed on either of the tracks (in the pair), the derail will remain activated and locked. If at all possible, the construction supervisor will stop work on the track and ensure all of his people and equipment are out of harm s way when the switch engine is in the plant. c. If switching can be safely performed on both tracks (in the pair, the construction supervisor will stop work on the track, ensure all of his people and equipment are out of harm s way on the track being worked on (and the other paired track) and will remove his lock from the derail. The Car Leader Man will then remove his lock and deactivate the derail. After switching has been completed on the track pair where the crew is working, he will reinstall his lock onto the derail (Car Leader Man locked and activated).

4 Procedure No.: SOP-0135 Page: 4 of 8 NOTE! d. If switching can safely occur on only one track in the pair, the construction supervisor will stop work on the track and ensure all of his people and equipment are out of harm s way. He will remove his lock from the derail and lock the common (shared) switch in one direction to protect the proper track in the pair (but allow the other track to have car movement take place). If the Car Leader Man has already locked the switch in the opposite direction, the construction supervisor should contact the Car Leader Man and discuss the situation. After switching has been completed on the track pair where his crew was working, he will remove his lock from the switch and reinstall his lock on the activated derail For Tracks Not Grouped In Pairs (Tracks 5, 7, and 8) a. The construction supervisor will attach his safety lock the already activated derail (which has a Car Leader Man's lock on it) before starting any work on a track. If the derail is not already activated and locked, the construction supervisor should find out why. b. If switching cannot be safely performed on the track, the derail will remain activated and locked. If at all possible, the construction supervisor will stop work on the track and ensure all of his people and equipment are out of harm s way when the switch engine is in the plant. c. If switching can safely occur on the track, the construction crew supervisor will stop work on the track and ensure all of his people and equipment are out of harm s way on the track. Then he will remove his lock from the derail. The Car Leader Man will then remove his lock and deactivate the derail. After switching has been completed, he will reinstall his lock onto the (Car Leader Man's locked and activated) derail. One reason for pairing the tracks is if some type of work is being performed on one track in the pair, the Shift Leader, Maintenance supervisor, or construction crew supervisor overseeing the work should consider if car movement on the other track in the pair endangers workers. For example, if loading or maintenance personnel are doing work on track 7A, they may be in such close proximity to track 7B with their working, walking, equipment set-up, etc., that they would be in harm s way in relation to car movement on track 7B. Any time work is being performed on a track during the hours that a plant switch occurs, the Shift Leader, Maintenance Supervisor, or Construction Crew Supervisor should contact the Car Leader Man prior to setting up on the track they are performing work on so the Car Leader Man will know work is being performed in the area.

5 Procedure No.: SOP-0135 Page: 5 of 8 Edgar Plant Purpose: The purpose of this procedure is to establish a Zero Energy State when working in or on moving parts of a calciner. Procedure: The procedure is intended to clarify auxiliary motor lockout on the Edgar Plant Calciners and does not supersede or void any part of the BASF Lock, Tag and Try Procedure. MECHANICAL CLUTCH The Mechanical Clutch is to be locked-out at all times when your work requires you to: 1. Be on the calciner 2. In the calciner 3. Working on or in close proximity to any unguarded moving part of the calciner EQUIPMENT REQUIREMENTS MINERALS 1. Crew Locks 2. Individual Locks 3. Multiple Lock Hasps 1. Crew Locks may be placed by an BASF or contractor crew supervisor to protect his crew while work is being performed on the calciner. This supervisor is directly responsible for the Accountability and Safety of his crew members prior to removing his lock or activating the mechanical clutch. All crew locks must have a Danger tag displaying the owner s identification. 2. Individual Locks require the same identification requirements and are to be used by personnel not protected by a crew lock. Mine Pipeline Lockout Procedure Once the area requiring repair or maintenance has been identified, the appropriate designee(s) for the work crew(s) will contact the site mill operator(s)/helper(s) where the pump and/or other sources of energy need to be locked out.

6 Procedure No.: SOP-0135 Page: 6 of 8 A telephone number that can be used to contact the designee(s) will be left with the mill operator/helper, so they can notify the designee when lockout is complete. Once contacted, the mill operator/helper will lock out the pump by placing the switch lever to the off position, attaching a tag, and placing an Owning/Operating Lock(s) on the switch(s). The tag attached to the Owning/Operating Lock will have the operator s/helper s job title and the name of the crew doing the work printed on it. The key to the lock will be controlled by the operator/helper performing the lock out. Other energy sources that could cause a hazard will be tagged or locked out as necessary. A separate Owning/Operating Lock and tag will be used for each crew working on the pipeline. For example, two crews working on same pipeline will use two separate locks. Each lock will be tagged for each crew. A separate Pipeline Lockout Form should be filled out for each crew working on the line. The mill operator/helper will record on the Pipeline Lockout Form, the information about the work being done. The designee s name must be logged, since the designee is the only individual authorized to have the operator/helper remove their lock(s) and/or tag(s). Washington County operations will notify the Daveyville and Gordon Plants about pipeline work being performed. Gibraltar and Dixie operations will notify the Daveyville Plant about pipeline work being performed. Once all equipment has been properly tagged and locked out, the operator/helper will test the equipment to ensure the pumps will not start-up. When the steps outlined above have been accomplished, a representative of the Owning/Operating department must travel to the intended work site and complete a Safe Work Permit (SWP), with a representative of the Servicing Department. Other appropriate permits such as Line Break, Confined Space and Hotwork will be completed at this time. No work on or above the pipeline will begin until the permits are complete except as follows: It is permissible for the service crew to do the minimal work necessary to prevent or reduce the environmental impact from a leak. The service operator should assess the area from a safety standpoint, and if there are no hazards, they should build appropriate berms, ditches, diversions, etc. as necessary to contain the spill. Once this is complete, no further work would be allowed until all permits are in place. During a shift change the operator/helper will record on the Pipeline Lockout Form, all information on pipeline work being performed. The keys can then be transferred to the new operator/helper. The designee of the work crew will then be contacted to inform them of the change of operators /helpers.

7 Procedure No.: SOP-0135 Page: 7 of 8 If the designee of the work crew needs to be changed, a new Safe Work Permit is required. The original designee will contact the operator/helper that has the pumps locked out. The person s name and phone number that is replacing the original designee will then be logged on the Pipeline Lockout Form and he will then become the designee of the work crew. A representative of the Owning/Operating Department will then terminate the original SWP and complete a new SWP with the new designee. Other permits may be re-issued as appropriate and work can then re-commence. Upon completion of the pipeline work, the designee(s) for each crew will inform the operator/helper the pipeline work has been completed. The operator/helper will remove his/her tag(s) and/or lock(s)...daveyville and Gordon Plant will be contacted to coordinate pump start-up. The pumps will be started and the line inspected for leaks. If no leaks are present, the line can be re-buried (if applicable), and communicated to the operator/helper that all work is now complete. The Operator/Helper will then terminate and file the permit(s). The operator/helper will record in the log book, or on a form, all information about pipeline maintenance or repairs completed. The Daveyville/Toddville Plant to Edgar Plant pipeline, and the Klondyke water line, are not covered under this section. Work on these particular pipelines is covered by our regular Lock, Tag, and Try Procedure. Communication cannot be emphasized enough. This must be maintained and followed up for any procedure to work. If the pipeline to be worked on is located between Daveyville and Gordon, both Daveyville and Washington County must be contacted. The pumps and valves at Daveyville must be locked out and verified before work may begin. 5. RESPONSIBILITIES It is the responsibility of each person working on BASF s property to follow these additional requirements.

8 Procedure No.: SOP-0135 Page: 8 of 8 6. RELATED DOCUMENTS Section Revision Revised Date Revised By Edgar Plant Removed reference to Crew Lock WJK 7/12/10 All SOP Review EM 8/11/13 All SOP Review KMH 07/15/2018