MACHINE NUMBER SPACE HAZARDS SPACE DESCRIPTION #60103-107 DESIGNATION ACCEPTABLE ENTRY PROCEDURES Conveyors with moving parts, pulleys, gears, rollers COKE UNLOADING PIT 1. Conveyors are guarded, if guards are removed, lockout of system myst be completed. #60103-201 #60103-202 #60103-203 #60103-204 #60103-205 LIME & COKE BIN SYSTEM #60130-422 INDEXING FEEDER PIT #60103-607 CHARGE BUCKET Dusty atmosphere Mechanical belt feed into bin Engulfment by contents Entrapment in tapered bottom Fall hazard - 25' deep 1. Empty contents of bin, and close & lock bottom sliding door. 2. Perform lockout of infeed belt/conveyor. 3. Air monitoring myst be within acceptable limits. If entry must be done to remove build up of limestone on the sides of the bin - follow this alternative procedure: 1. Air monitoring must be within acceptable limits. 2. Perform lockout on infeed belt and conveyor. 3. Entry via rope ladder. Employee should be wearing a harness attached to a mechanical retrieval device and the line kept tight. 4. Bottom doors may be left open to facilitate the removal of the built up material. Feeders with moving parts. 1. Feeders are guarded, if guards are removed, lockout of the system must be completed. Feeder drops material into bucket & may engulf. Fall hazard - greater than 5' deep. 1. Employ contents of bucket, and secure bottom doors. 2. Lockout of feeder. 3. Lockout of charge hydraulics to prevent bucket movement. REV. 08.23.2017 1
MACHINE NUMBER SPACE HAZARDS SPACE DESCRIPTION DESIGNATION ACCEPTABLE ENTRY PROCEDURES #60103-107 #60110-463 Engulfment in contents HOT OIL EXPASION TANK Fall hazard Possible toxic atmosphere #60110-464 HOT OIL DRAIN TANK 1. Empty contents, may need to rinse tank. 2. Portable ladder. 3. Air monitoring results must be acceptable prior to entry. 4. Lockout oil pumps. #60130-608 CHARGE BUCKET PIT #60110-100 CUPOLA BOTTOM DOOR CLOSED BOTTOM DOOR OPEN Charge bucket moving in and out of pit. 1. Lockout charge bucket to prevent movement of the bucket. 2. Lockout inexing conveyor. Possible toxic atmosphere Fall hazard (100') Mechanical & electrical equipment used for repair work BOTTOM DOOR CLOSED: 1. Perform bottom drop procedure, empty contents, allow cooling time. 2. Lockout charge system, oxygen system, nitrogen system, blast blowers, level gauges & any other related equipment. 3. Spray & purge for a minimum of 4 hours. 4. Air testing must demonstrate acceptable air quality. BOTTOM DOOR OPEN: 1. Perform bottom drop procedure, empty contents, allow cooling time. 2. Lockout charge system, oxygen system, blast blowers, level gauges & any other related equipment. 3. Spray & purge for a minimum of 4 hours. #60110-102 DRUM Excessive temperature Extreme forced air Possible toxic atmosphere (carbon monoxide) 1. Cupola shutdown procedure & lockout of related equipment. 2. Lockout of blast blower. 3. Air testing must demonstrate acceptable air quality. REV. 08.23.2017 2
MACHINE NUMBER SPACE HAZARDS SPACE DESCRIPTION DESIGNATION ACCEPTABLE ENTRY PROCEDURES #60103-107 #60140-200 #60140-300 90 TON FURNACE (2) Fall protection - bottom open when indcutors removed Temperature Dust & noise during relining process Hydraulics ". CONTENTS EMPTIED AND SYSTEM COOLED." 1. Lockout hydraulic mechanism of furnace. 2. Pin furnace to prevent movement. 3. Block opening in bottom of furnace when inductors removed, alternate fall protection if shoveling out of this space. 4. Provide continuous ventilation during refractory work. 5. Ground fault protection for any portable equipment used inside of the furnace. #60140-400, 450 #60140-500, 550 #60140-600, 650 AUTO POURS #60110-106 GAS TAKE OFF DUCT #60110-330 HOT BLAST DUCT Electrical hazard near inductors Fall hazard into pit (5') Movement of furnace 1. Lockout hydralics to furnace, and electric to inductors. 2. External barrier to prevent a fall hazard into the pit. Excess heat Toxic atmosphere (carbon monoxide) exhausts of cupola Fall hazard - into cupola and Coarse Grain Seperator 1. Perform bottom drop, and shut down of cupola system. 2. Lockout of all related equipment. 3. Allow ventilation cooling time, 5 hours minimum cooling time. 4. Air testing must be within acceptable limts. Excess heat Toxic atmosphere, possible low oxygen level High dust level 1. Allow 24 hours cooling. 2. Lockout all related equipment. 3. Air testing must be within acceptable limits. REV. 08.23.2017 3
MACHINE NUMBER SPACE HAZARDS SPACE DESCRIPTION DESIGNATION ACCEPTABLE ENTRY PROCEDURES #60103-107 #60110-480 #60110-485 CUPOLA EXHAUSTER BLOWER - exhauster fan Possible build up of toxic gases (carbon monoxide) HOUSING VENTILATION PROCEDURE: 1. Ventilate system for 30 minutes to eliminate possible toxic gases. 2. Lockout related equipment, including the fan. 3. Provide continuous ventilation during entry. 4. Air testing must demonstrate acceptable limits. #60110-490 EXHAUSTER BLOWER STACK (OFF EXHAUSTER FAN) Possible toxic gases off system (carbon monoxide) Possible heavy metal airborne dust #60110-511 BAGHOUSE/DAY TANK * TO BE ENTERED WHEN SYSTEM IS DOWN 1. Purge system with blower/exhauster. 2. Lockout related equipment. 3. Air testing must demonstrate acceptable limits. 4. Cool for 4 hours. Possible toxic gases Flammable gases Oxygen deficient Airborne dust Engulement hazard 1. Empty contents. 2. Cool for 4 hours. 3. Ventilate. 4. Lockout P.D. blowers, air system for transporter and all systems related to bag houses. 5. Air testing must demonstrate acceptable limits. REV. 08.23.2017 4
MACHINE NUMBER SPACE HAZARDS SPACE DESCRIPTION DESIGNATION ACCEPTABLE ENTRY PROCEDURES #60103-107 #60110-501, 502, 503, 504, 505, 506, 507, 508, 509, 510 BAGHOUSE (10) Possible toxic gases Flammable gases Oxygen deficient Airborne dust atmosphere 1. Empty contents. 2. Cool for 4 hours. 3. Ventilate. 4. Lockout P.D. blowers and exhauster fans. 5. Air testing must show acceptable air quality. #60110-408 COMBUSTION CHAMBER #60110-431 RECOUPERATOR TOWER #60110-251 HOT WELL TANK ** Note: lockout of dampers will allow production entry. Possible toxic atmosphere Flammable atmosphere Fall hazard 1. Cool for 24 hours. 2. Ventilate 5 hours with Combustion Blower. *Can run exhausters at no more than 30% for cooling and ventilation* 3. Lockout burners, and combustion air blower. 4. Air testing must show acceptable air quality. Possible toxic atmosphere Flammable atmosphere Fall hazard 1. Cool for 24 hours. 2. Ventilate 5 hours with Combustion Blower. 3. Lockout exhauster, burners, and combustion air blower. 4. Air testing must show acceptable air quality. Engulfment Fall hazard 1. Empty contents of tank & block inflow. 2. Lockout: cooling tower pumps, recirculation pumps, tuyere pump and cupola pump. 3. Air monitoring must demonstrate acceptable air quality. REV. 08.23.2017 5
MACHINE NUMBER SPACE HAZARDS SPACE DESCRIPTION DESIGNATION ACCEPTABLE ENTRY PROCEDURES #60103-107 #60110-252 COLD WELL TANK Engulfment Fall hazard 1. Empty contents of tank & block inflow. 2. Lockout: cooling tower pumps, recirculation pumps, tuyere pump and cupola pump. 3. Air monitoring must demonstrate acceptable air quality. #60110-405 COARSE GRAIN SEPERATOR #60110-435 TRANSTION DUCT #60110-412, 413, 414 COMBUSTION AIR DUCT WORK Possible toxic atmosphere Flammable atmosphere Fall hazard 1. Cool for 5 hours. 2. Ventilate for 5 hours. 3. Lockout: exhauster, burners, and combustion air blower. 4. Air monitoring must show acceptable air quality. Possible toxic atmosphere Entrapment 1. Cool for 5 hours. 2. Ventilate for 5 hours. 3. Lockout: exhauster, burners, and combustion air blower. 4. Air monitoring must show acceptable air quality. NON ENTRY #60110-320 COLD BLAST DUCT #60103-422 RETURNS CONVEYOR PIT Extreme forced air Possible toxic atmosphere 1. Cool for 8 hours. 2. Cupola shutdown procedure. 3. Lockout blast blower. 4. Air monitoring must show acceptable air quality. Conveyors with moving parts, pulleys, gears, rollers 1. Conveyors are guarded, if guards are removed, lockout of system myst be completed. REV. 08.23.2017 6
MACHINE NUMBER SPACE HAZARDS SPACE DESCRIPTION DESIGNATION ACCEPTABLE ENTRY PROCEDURES #60103-107 #60110-512 BAGHOUSE INTLET DUCT Engulfment Possible toxic, flammable, oxygen deficient, and airborne dust atmosphere #60110-513 BAGHOUSE OUTLET DUCT #60140-201 #60140-301 FURNACE PIT (2) #60140-401, 451, 501, 551, 601, 651 AUTO POUR PITS (6) #60110-209, 210, 211 COOLING TOWER "WEST, CENTER, EAST" 1. Empty contents. 2. Cool for 4 hours. 3. Ventilate for 4 hours. 4. Air monitoring must show acceptable air quality. Engulfment Possible toxic, flammable, oxygen deficient, and airborne dust atmosphere 1. Empty contents. 2. Cool for 4 hours. 3. Ventilate for 4 hours. 4. Air monitoring must show acceptable air quality. Electrical hazard - inductors Movement of furnace 1. Lockout hydraulic mechanism of furance 2. Pin furnace to prevent movement. 3. Lockout inductors. Electrical hazard - inductors Movement of furnace 1. Lock out hydraulic mechanism of furnace. 2. Pin furnace to prevent movement. 3. Lockout inductors. VENTILATION PROCEDURE: Toxic gases Engulfment 1. Place the system into "bypass" mode or enter during non production periods only. 2. Allow natural ventilation of the space (open ends to outside). Fan Can ben used for additional ventilation. 3. Pre entry and continuous air monitoring must be within acceptable limitations. REV. 08.23.2017 7
MACHINE NUMBER SPACE HAZARDS SPACE DESCRIPTION DESIGNATION ACCEPTABLE ENTRY PROCEDURES #60103-107 #69199-400 DUCTWORK & STACKS (GENERAL DUCTWORK) #69199-613 DUCTILE DUCTWORK STACKS: #69199-500 SO1 - MAIN PLANT OPS STACK Toxic atmosphere, low level of cabon monoxide, amine gas, sulfur dioxide, dusty atmosphere. S10 - CUPOLA #69199-613 S12 DUCTILE S23 - CORE SCRUBBER 1. Air monitoring must be acceptalbe prior to and during entry. 2. Continuous ventilation required - a portable blower may be necessary. 3. Lockout equipment related to ductwork (blowers, etc.) or stack to prevent emissions from interfering with entry. MONOFILL LIFT STATION PLANT 6 MONOFILL SAND STORAGE Lime Storage Silo Fall hazard great than 4' Possible toxic atmosphere Animals and insects Possible electrical hazard - lift pumps Engulfment - water 1. Continuous air monitoring. 2. Pump out all water in tank. 3. Lockout lift pumps before entering. Dusty atmosphere Potential of engulfment Fall hazard greater than 4 feet Pneumatic in-feed, top of silo Mechanical auger in bottom of silo 1. Block pneumatic in-flow of lime 2. Empty contents of silo. 3. Lockout auger in bottom. 4. Air monitoring must demonstrate acceptable air quality. 5. Fall protection with mechanical retrieval required. REV. 08.23.2017 8
REQUIRED ENTRY EQUIPMENT FREQUENCY OF ENTRY None DAILY 1. Multi-gas air monitor 2. Body harness attached to a mechanical retrieval device 3. Portable ladder ANNUALLY None DAILY 1. Portable ladder WEEKLY REV. 08.23.2017 9
REQUIRED ENTRY EQUIPMENT FREQUENCY OF ENTRY 1. Multi-gas air monitor 2. Body harness attached to a mechanical retrieval device. 3. Portable ladder ENTRY NOT EXPECTED None WEEKLY 1. Body harness/lanyard attached to a manbasket with mechnical retrieval. WEEKLY OR AS NEEDED FOR REPAIRS 1. Multi-gas air monitor AS NEEDED FOR MAINTENANCE REV. 08.23.2017 10
REQUIRED ENTRY EQUIPMENT FREQUENCY OF ENTRY 1. Fall protection when inductors are removed. 2. Portable ventilation. 3. Ground fault protection on portable equipment. ANNUAL OR AS NEEDED FOR REPAIRS CONTRACTED REFRACTORY WORK 1. Portable ladder ANNUALLY OR AS NEEDED FOR REPAIRS 2. Body harness attached to mechanical retrieval system. 2 TIMES PER YEAR 3. Dust mask may be needed. ANNUALLY REV. 08.23.2017 11
REQUIRED ENTRY EQUIPMENT FREQUENCY OF ENTRY 2. Portable blower. AS NEEDED TO CLEAN OUT BUILD UP MONTHLY AS NEEDED FOR WORK ON VALVE OR REPAIR WORK ON BURNER REV. 08.23.2017 12
REQUIRED ENTRY EQUIPMENT FREQUENCY OF ENTRY QUARTERLY INSPECTION OR AS NEEDED FOR WORK MONTHLY OR AS NEEDED FOR CLEANING SEMI-ANNUALLY SEMI-ANNUALLY REV. 08.23.2017 13
REQUIRED ENTRY EQUIPMENT FREQUENCY OF ENTRY SEMI-ANNUALLY WEEKLY WEEKLY - DURING SHUTDOWN ANNUALLY None DAILY REV. 08.23.2017 14
REQUIRED ENTRY EQUIPMENT FREQUENCY OF ENTRY AS NEEDED FOR MAINTENANCE AS NEEDED FOR MAINTENANCE AS NEEDED FOR MAINTENANCE AS NEEDED FOR MAINTENANCE AS NEEDED FOR MAINTENANCE REV. 08.23.2017 15
REQUIRED ENTRY EQUIPMENT FREQUENCY OF ENTRY 2. Portable blower may be necessary. 3. Full body harness attached to a life line. 4. Mechanical retrieval if doing work on any of the vertical drops in ductwork that are more than 5' deep. AS NEEDED FOR MAINTENANCE NO HOT WORK ALLOWED!! 2. Body harness attached to a mechnical retrieval device. 3. Portable ladder. AS NEEDED FOR MAINTENANCE 2. Body harness attached to mechanical retrieval device. 3. Portable ladder. AS NEEDED FOR MAINTENANCE REV. 08.23.2017 16