NW Sulfuric Jsha

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

1
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
2
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
3
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
4
Job Safety Analysis
Sulfuric Acid Plants
Date: 5/19/92
Revised: 6/30/97
Written By: London
Reviewed By: MEB
Procedure Number: NWF-JSA-001
Task:Open/Close Product Acid Valve
Work Step Potential Hazards Corrective Action

1. Open or Close Block Valve Acid Leaks Wear Acid Jacket, Face Shield, Rubber Gloves and
Goggles.
5
Job Safety Analysis
Date: 6/1/89
Revised: 6/30/97
Written By: A. Taylor
Reviewed By: MEB
Task:DIP IPA and Final Pump Tanks

1. 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 Acid burns Same as # 1.
touches bottom, and remove rod.
3. Check measurement on rod for amount of acid Acid burns Same as # 1.
in tank.
4.
6
Job Safety Analysis
Date: 7/24/89
Revised: 6/30/97
Written By: P. Iannone
Reviewed By: M.E.B.
Task:Catch acid samples at pump tanks.

1. 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 rubber
gloves.
3. Open acid sample valve slowly and fill sample Acid splash or acid leak. Wear acid jacket, face shield, goggles, and rubber
bottle. gloves.
4. Rinse sample bottle with acid then refill Acid splash or acid leak. Wear acid jacket, face shield, goggles, and rubber
sample bottle. gloves.
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 Acid splash. Same as step four.
with water.
7
Job Safety Analysis
Date: 5/11/89
Revised: 6/30/97
Written By: K. Anderson
Reviewed By: MEB
Task: Fill pump tanks with acid ( after t/a )

1. 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 Same as step one. Same as step one.
receive acid.
4. Open transfer valves on plants that will send Same as step one. Same as step one.
acid.
8
Job Safety Analysis
Date: 1/9/90
Revised: 7/1/97
Written By:
Reviewed By: MEB
Task: Transfer acid from one plant to another.

1. 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 Acid leaks. Wear acid jacket, face shield, goggles and gloves.
IPA header a maximum of two rounds.
4. Inspect acid transfer line for leaks. Acid leaks. Wear acid jacket, face shield, goggles and gloves.
9
Job Safety Analysis
Date: 8/23/90
Revised: 7/1/97
Written By:
Reviewed By: MEB
Task: Drain acid seal leg.

1. Make sure area is barricaded. None. None.
2. Make sure acid drain hose is connected and on None. None.
pad.
3. Open acid drain valve. Chemical burns and falling. Wear full acid suit, l face shield, goggles, gloves
and boots. Use 3-Point stance on ladder or safety
belt on high reach.
4. Rinse pad with water. Chemical burns. Wear full acid suit, face shield, goggles, gloves and
boots.
10
Job Safety Analysis
Date: 7/15/93
Revised: 7/1/97
Written By: K. Sams
Reviewed By: MEB
Task: Start up acid circulating pumps.

1. Check moisture drains. Chemical burns, hand injuries. Wear acid jacket, face shield, and gloves.
2. Check cooler exit and bypass valves for Burrs on valves. Wear gloves.
correct position.
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.
11
Job Safety Analysis
Date: 6/10/89
Revised: 7/1/97
Written By: K. Sams
Reviewed By: MEB
Task: Shut down acid circulation pumps.

1. 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.
12
Job Safety Analysis
Date: 9/14/92
Revised: 7/1/97
Written By: O. Jennings
Reviewed By: MEB
Task: Adjust acid flow over towers.

1. 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 Same as one. Same as one.
close valves as needed.
13
Job Safety Analysis
Date: 9/13/92
Revised: 7/1/97
Written By: O. Jennings
Reviewed By: MEB
Task: Pump out pump tanks.

1. 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 Chemical burns. Same as one.
pump and from drain pump to transfer line out
of plant.
3. Open valves on transfer line into plant Chemical burns. Same as one.
receiving acid.
4. Start drain pump. Chemical burns. Same as one.
14
Job Safety Analysis
Date: 7/16/89
Revised: 7/1/97
Written By: K. Taylor/Rick Rice
Reviewed By: MEB
Task: Stick test on towers.

1. 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 Acid mist, chemical burns. Wear acid jacket, face shield, goggles, and rubber
minute, remove stick, and close valve. 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.
15
Job Safety Analysis
Date: 4/18/89
Revised: 7/1/97
Written By: L. Spell
Reviewed By: MEB
Task: Pump out CIL coolers. (acid side).

1. Open valves to pump tank which will receive Acid leaks/chemical burns. Wear acid suit, face shield, goggles, and rubber
acid. gloves.
2. Open valves on CIL cooler drain lines to acid Same as one. Same as one.
drain pump.
3. Start drain pump. Same as one. Same as one.
4. After coolers are empty, Shut down drain Same as one. Same as one.
pump.
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.
16
Job Safety Analysis
Date: 5/11/89
Revised: 7/1/97
Reviewed By: MEB
Task: Drain CIL coolers (water side).

1. 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.
17
Job Safety Analysis
Date: 2/11/90
Revised: 7/1/97
Written By: C- Shift
Reviewed By: MEB
Task: Back flush CIL coolers(water side).

1. 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 Rough valve handles and chain operators. Heavy Wear gloves clear area, Post watchman.
valve to backflush cooler. volume of water out of south door.
4. Close exit valve. Same as one. Wear gloves.
18
Job Safety Analysis
Date: 5/14/89
Revised: 7/1/97
Written By: T. Mc Bride
Reviewed By: MEB
Task: Caustic wash acid tower.

1. 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 Chemical burns. Wear acid suit , face shield, goggles, and rubber
approximately five minutes. 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 Chemical burns. Wear acid jacket, face shield, goggles, and rubber
circulating. gloves.
9. Drain all caustic water from pump tanks, seal Chemical burns. Wear acid jacket, face shield, goggles, and rubber
legs, and CIL coolers. 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.
19
Job Safety Analysis
Date: 9/12/92
Revised: 7/18/97
Written By: Kent Anderson
Reviewed By: MEB
Task: Bypass Dilution Tank.

1. 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 Same as one. Same as one.
make sure recycle valve is open.
3. Close outlet valve on dilution product line to Same as one. Same as one.
tank farm.
4. When everyone is clear of the dilution tank, None. None.
call the chief, to shut down the dilution acid
pump.
20
Job Safety Analysis
Date: 2/11/90
Revised: 7/1/97
Written By: C- Shift
Reviewed By: MEB
Task: Valve in boiler sight glasses.

1. Place safety chain back on sight glass. Steam/or Hot water. Thermal burns. Wear gloves.
2. Close drains on bottom of sight glasses and Same as one. Same as one.
water column.
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.
21
Job Safety Analysis
Date: 2/11/90
Revised: 7/2/97
Written By: C-Shift
Reviewed By: MEB
Task: Valve out boiler sight glasses.

1. Close top steam valve from boiler to water Steam and or hot water. Thermal burns. Wear gloves.
column.
2. Close bottom water valve from boiler to water Same as one. Same as one.
column.
3. Open drains on bottom of water column and Same as one. Same as one.
sight 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.
22
Job Safety Analysis
Date: 6/8/89
Revised: 7/2/93
Written By: Willie Edwards
Reviewed By: MEB
Task: Blow boilers down manually.

1. 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 Same as one. Same as one.
approximately 15 sec..
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 Same as one. Same as one.
down block valves.
23
Job Safety Analysis
Date: 5/1/90
Revised: 7/2/97
Written By: Ron Pierce
Reviewed By: MEB
Task: Depressure and drain boilers.

1. After plant is shut down. Close both block Hand injuries. Wear leather gloves.
valves on steam drum.
2. Start manually blowing down boilers Hand injuries. Wear leather gloves.
continuously controlling with outside blow
down valve.
3. When pressure gets down to 100lbs.. Start Hand injuries. Wear leather gloves.
adding well water through well water line.
Open drain to ditch.
4. When pressure reaches 25lbs. Open vent on Hot water and steam shooting out of vent, thermal Wear acid jacket, face shield, and leather gloves.
top of steam drum. burns.
5. When pressure reaches 0lbs. Discontinue well Hand injuries. Wear leather gloves.
water and let boilers drain through open drain
valves.
24
Job Safety Analysis
Date: 9/14/92
Revised: 7/2/97
Written By: C. Walker
Reviewed By: MEB
Task: Check boiler level trip(plant shutdown)

1. Slow blower to 10”. Clear furnace of sulfur. Thermal burns. Wear gloves.
2. Close bottom valve to Eye- Hye , and open Thermal burns. Wear gloves.
Eye-Hye drain valve.
3. Confirm that blower tripped. Thermal burns. Wear gloves.
4. Close Eye-Hye drain valve, and open bottom Thermal burns. Wear gloves.
valve to Eye-Hye.
25
Job Safety Analysis
Date: 7/9/90
Revised: 7/1/97
Written By: D-shift
Reviewed By: MEB
Task: Put OA Superheater in service.

1. Before plant is heated up OA inlet, outlet, and Burrs on valve handles, Hand injuries. Thermal Wear gloves.
automatic valves are closed, and drain and burns.
vent valves are opened.
2. Before putting plant on sulfur. Close drain Burrs on valve handles, Hand injuries . Thermal Wear gloves.
valves, and check that valves are open to traps. burns.
3. Slowly open outlet block valves until OA Burrs on valve handles, Hand injuries, Thermal Wear gloves.
starts to pressurize. Close vent valves when air burns.
is purged from OA.
4. When OA is pressurized, open outlet valve Burrs on valve handles, Hand injuries, Thermal Wear gloves.
100% . Leave automatic valve in manual and burns.
closed until, after plant is on sulfur.
5. Open inlet block valve 100%. Burrs on valve handles, Hand injuries, Thermal Wear gloves.
burns.
6. Check that traps are working. Burrs on valve handles , Hand injuries, Thermal Wear gloves.
burns.
26
Job Safety Analysis
Date: 6/1/90
Revised: 7/2/97
Written By: A-shift
Reviewed By: MEB
Task: Put 4A Superheater in service.

1. Before(plant heat up) close inlet manual valve. Burrs on valve handles, hand injuries. Wear gloves.
Open outlet valve. Close automatic valve.
2. Open vents and drains valves on 4A Burrs on valve handles, hand injuries. Wear gloves.
Superheater.
3. Check that the battery limits Superheated Burrs on valve handles, hand injuries, thermal Wear gloves.
steam valve remains closed. burns.
4. During heat when 4th pass outlet temp reaches Burrs on valve handles, hand injuries, steam and Wear gloves.
475 deg. Close drains and vents on 4A and hot water, thermal burns.
superheated steam line. Open superheated
steam valve at battery limits.
5. Before plant goes on sulfur open manual inlet Burrs on valve handles, hand injuries, steam and Wear gloves.
valve, Automatic valve stays closed until plant hot water, thermal burns.
goes on sulfur.
27
Job Safety Analysis
Date: 5/14/89
Revised: 7/1/97
Written By: T. McBride
Reviewed By: MEB
Task: Depressurize Superheater.

1. After plant is down and secured. Close inlet Thermal burns, high pressure steam, rough valve Wear gloves, avoid leaks and hot surfaces.
and exit manual steam valves. handles.
2. Open vents. Same as one. Same as one.
3. Open drains on steam traps and superheater. Same as one. Same as one.
28
Job Safety Analysis
Date: 3/26/90
Revised: 7/2/97
Written By: A-shift
Reviewed By: MEB
Task: Back Saturated Steam into plant.

1. Partially open condensate drain valves in Thermal burns from hot water and steam. Wear gloves. Stand to one side when opening drain
plant. valves.
2. Partially open 600lb. Saturated Steam valve to Climbing, Hand injuries, thermal burns, water Maintain three point stance. Wear gloves, Open
plant. hammer. valve slowly.
3. Close drain valves when only steam is coming Same as one. Same as one.
out.
4. After Saturated Steam header is pressurized Same as two. Same as two.
slowly open Saturated Steam valve to 100%.
29
Job Safety Analysis
Date: 2/10/90
Revised: 7/2/97
Written By: C-shift
Reviewed By: MEB
Task: Put Flash Tank in Service.

1. 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.
30
Job Safety Analysis
Date: 5/14/89
Revised: 7/2/97
Reviewed By: MEB
Task: Drain Economizers.

1. Shut down feedwater pump to plant. None. None .
2. Close inlet and outlet valves to section to be Rough valve handles, hand injuries, thermal burns. Wear gloves.
drained.
3. Open drains, and vent valves. Same as two. Place board under drain so a large hole is not dug in
ground or asphalt. Open valves slowly, standing to
one side. Wear gloves.
31
Job Safety Analysis
Date: 3/28/91
Revised: 7/7/97
Written By: J. Ragoonanan
Reviewed By: MEB
Task: Start up Keystone boiler.

1. Open feedwater valves to boiler. Bring boiler Over filling boiler, may put water in steam lines Monitor water level while filling boiler. Wear
water level to operating level. causing a water hammer. Rough valve handles. gloves.
2. Open steam drum block valve. Relief valve may open If boiler over pressures, due Make sure block valve is open.
to steam drum block valve being closed.
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.
32
Job Safety Analysis
Date: 7/16/89
Revised: 7/8/97
Written By: R. Rice
Reviewed By: MEB
Task: Run Sulfur Gun survey.

1. 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 Same as 1. Same as 1.
guns.
4. * Note: Wear green welders coat instead of acid
jacket.
33
Job Safety Analysis
Date: 6/8/89
Revised: 7/8/97
Reviewed By: MEB
Task: Valve out steam on sulfur guns.

1. Check that sulfur gun cooling steam drain Explosion. If both inlet and outlet steam lines are Wear gloves. Make sure drains are not plugged.
lines are open. blocked. Pressure could build up in guns. Thermal
burns.
2. Close sulfur gun inlet cooling steam valve. Thermal burns. Wear gloves, and avoid contact with hot steam
lines.
3. *Note: Wear green welders jacket on sulfur
platform.
34
Job Safety Analysis
Date: 5/13/89
Revised: 7/8/97
Written By: S. Henry
Reviewed By: MEB
Task: Unplugging Sulfur Guns.

1. Check to make sure gun and sulfur lines are Hot steam and hot sulfur. Wear face shield, acid jacket, and leather gloves.
hot.
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.
35
Job Safety Analysis
Date: 3/26/90
Revised: 7/8/97
Written By: A shift
Reviewed By: MEB
Task: Put Sulfur Gun in service.

1. 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 Thermal burns. Same as 1.
enough to melt sulfur.
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.
36
Job Safety Analysis
Date: 5/22/89
Revised: 7/10/97
Written By: J. Ragoonanan
Reviewed By: MEB
Task: Put Steam on Sulfur Guns.

1. 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.
37
Job Safety Analysis
Date: 6/3/89
Revised: 7/10/97
Written By: Holcomb
Reviewed By: MEB
Task: Start Oil Fire.

1. Check that dampers and start up stack are set None. None.
up for oil fire.
2. Start air compressor and open air valve to oil Air leaks. Make sure hose connections are tight and pinned.
gun.
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 Barricade area at boiler manways.
boiler manways.
5. Stick torch in bucket of #2 fuel oil and Spill fuel oil. Bucket should set flat on surface.
remove.
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 from
hole.
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 Thermal burns. Stick lit end of torch directly into fuel oil bucket.
fire. Fuel oil should be deep enough to cover entire
flame at once.
11. Adjust fuel oil valve to gun according to Thermal burns. Wear gloves.
temperature.
38
Job Safety Analysis
Date: 6/3/89
Revised: 7/10/97
Written By: London
Reviewed By: MEB
Task: Watch Oil Fire on heat up.

1. Watch oil fire. Fire going out and oil collecting in bottom of Shut off oil gun.
furnace.
2. *Note: Wear green welders jacket.
39
Job Safety Analysis
Date: 2/11/90
Revised: 7/1/97
Written By: C shift
Reviewed By: MEB
Task: Change oil tip during oil fire heat up.

1. 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.
40
Job Safety Analysis
Date: 2/11/93
Revised: 7/10/97
Written By: C shift
Reviewed By: MEB
Task: Changing fuel oil filters during oil fire heat up.

1. 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.
41
Job Safety Analysis
Date: 6/1/89
Revised: 7/10/97
Written By: G. London
Reviewed By: MEB
Task: Adjust plant dampers.

1. 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 Closing both dampers on one boiler will smother At no time while the plant is on sulfur should the
as directed by chief. the fire in the furnace. Reopening one of the #1 or #2 boiler exit and bypass dampers be closed
dampers will cause a sulfur explosion. at the same time. Always open one damper 100%
before closing the other.
42
Job Safety Analysis
Date: 5/14/89
Revised: 7/10/97
Reviewed By: MEB
Task: Obtain Plant Readings.

1. Walk through plant and obtain readings. Acid burns, thermal burns, and gas fumes. Look for leaks in area and report.
43
Job Safety Analysis
Date: 8/23/90
Revised: 7/10/97
Written By:
Reviewed By: MEB
Task: Checking Stack Drain.

1. 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.
44
Job Safety Analysis
Date: 5/1/90
Revised: 7/10/97
Written By: Ron Pierce
Reviewed By: MEB
Task: Check moisture drains, Boilers and economizers.

1. 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.
45
Job Safety Analysis
Date: 6/1/89
Revised: 7/10/97
Written By: London
Reviewed By: MEB
Task: Barricade acid leaks.

1. Rope off area with red barricade tape. Chemical burns. Wear face shield, goggles, acid suit, and gloves.
46
Job Safety Analysis
Date: 5/13/89
Revised: 7/10/97
Reviewed By: MEB
Task: Caustic Wash Main Compressor.

1. Shut down compressor. Thermal burns. Wear gloves.
2. Have maintenance open manway on suction None. None.
duct.
3. Connect water and steam hoses to compressor Thermal burns. Wear gloves.
drain pipe.
4. Open valve from stand pipe to blower drain Chemical burns. Wear face shield, goggles, acid suit, and rubber
line and pour 5 gallons of caustic into gloves.
compressor.
5. Close valve from stand pipe. Open valve from Chemical burns. Same as 3.
water hose to drain pipe, and fill compressor
part way with water.
6. Open valve from steam hose to compressor Thermal burns, hose rupture. Wear gloves. Inspect hose for wear. Make sure
drain line. safety pins are used.
7. Slow roll compressor. Thermal burns, chemical burns. Caustic solution Wear face shield, goggles, acid suit, and gloves.
splashing out of manway. Barricade area around manway.
47
Job Safety Analysis
Date: 7/21/89
Revised: 7/10/97
Written By: B. English
Reviewed By: MEB
Task: Shut down Main Blower.

1. Make sure that auxiliary lube oil pump comes None. None.
on.
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.
48
Job Safety Analysis
Date: 12/25/92
Revised: 7/10/97
Reviewed By: MEB
Task: Start up Main Blower.

1. Open drains on steam trap to 575# and 45# Thermal burns, and hand injuries. Wear gloves.
steam lines to turbine.
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 Same as 1. Same as 1.
throttle valve.
5. When steam is dry and hot, close drain valves Same as 1. Same as 1.
on steam traps.
6. Turn on auxiliary oil pump. Check oil pressure None. None.
and level in reservoir.
7. Check oil in governor. None. None.
8. Open trip and throttle valve an slow roll Same as 1. Same as 1.
turbine for 30min.. If coming off turn around.
If down for 1 hour or more slow roll for
20min..
49
Job Safety Analysis
Date: 1/12/90
Revised: 7/14/97
Written By: GGR
Reviewed By: MEB
Task: Start up #6 Fuel Oil Dispensing Pump.

1. Open inlet and discharge valves on pump. Hand injuries . Wear gloves.
2. Start pump. Oil leaks. Shut off pump.
50
Job Safety Analysis
Date: 9/14/92
Revised: 7/14/97
Written By: Oliver Jennings.
Reviewed By: MEB
Task: Start #2 Fuel Oil Pump.

1. Open inlet and discharge valves on pump. Hand injuries. Wear gloves.
2. Start pump. Fuel oil leaks. Shut down pump.
51
Job Safety Analysis
Date: 2/12/90
Revised: 7/14/97
Written By: GGR
Reviewed By: MEB
Task: Start Up Well Water Pumps.

1. 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 Same as 1. Same as 1.
valve 100%
52
Job Safety Analysis
Date: 7/14/97
Revised:
Written By: K. Eldridge
Reviewed By: MEB
Task: Bleach Cooling Tower.

1. 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 Bleach leaks. Turn pump off.
designated time.
3. Shut off bleach pump. None. None.
4. Close inlet and outlet valves to bleach pump. Chemical burns. Wear face shield, and rubber gloves.
53
Job Safety Analysis
Date: 2/12/90
Revised: 7/14/97
Written By:
Reviewed By: MEB
Task: Bypass Feedwater Heater.

1. Open continuous blowdown valves to Thermal burns. Hand injuries. Wear gloves.
atmosphere, and close valves to flash tank.
2. Close 5# steam valve and 5# bypass valve to Same as 1. Same as 1.
feedwater heater.
3. Close boiler feedwater heater recycle valves at Same as 1. Same as 1.
each boiler feedwater pump.
4. Close condensate return lines to feedwater Same as 1. Same as 1.
heater.
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.
54
Job Safety Analysis
Date: 6/6/89
Revised: 7/17/97
Written By: G. Nichols
Reviewed By: MEB
Task: Start up Boiler Feedwater Pump.

1. Valve in lubricating oil lines. None. None.
2. Start lubricating oil pump and check oil flow None. None.
to bearings.
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. Thermal burns, Hot water. Wear gloves.
When water comes out of air bleed valves
close valve back to allow a low flow from
pump until pump heats up.
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.
55
Job Safety Analysis
Date: 6/3/89
Revised: 7/17/97
Written By: London
Reviewed By: MEB
Task: Charge Chemical Day Tanks.

1. Drain chemicals from bulk tank to measuring Chemical burns. Wear acid jacket, face shield , goggles, and rubber
bucket. 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.
56
Job Safety Analysis
Date: 6/17/93
Revised: 7/17/97
Written By:
Reviewed By: MEB
Task: Start up Cold well Pumps.

1. 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.
57
Job Safety Analysis
Date: 6/3/89
Revised: 7/17/97
Reviewed By: MEB
Task: Run Water Samples in Lab.

1. 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.
58
Job Safety Analysis
Date: 5/22/89
Revised: 7/17/97
Written By: S. Henry
Reviewed By: MEB
Task: Establish Chlorination to Potable Water.

1. Open water valve to ejector. And check None. None.
vacuum.
2. Crack open discharge valve on cylinder and Chlorine leak. Wear rubber gloves, acid jacket, and full face
establish flow. respirator.
3. Open discharge valve on cylinder 100% and Same as 1. Same as 1.
adjust set point to get desired residual.
4. Open discharge valve on standby cylinder. Same as 1. Same as 1.
59
Job Safety Analysis
Date: 6/1/89
Revised: 7/21/97
Written By: G. Holcomb
Reviewed By: MEB
Task: Start up Diesel Deep Well Pump.

1. Shut down south deep well and lock out None. None.
motor.
2. Have maintenance connect shaft to diesel, as None. None.
per written procedure posted at the pump.
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.
60
Job Safety Analysis
Date: 6/1/89
Revised: 7/21/97
Reviewed By: MEB
Task: Start up Cooling Tower Fans.

1. 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.
61
Job Safety Analysis
Date: 5/13/89
Revised: 7/21/97
Written By: JAW
Reviewed By: MEB
Task: Start up Potable Water Pumps.

1. 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.
62
Job Safety Analysis
Date: 9/14/92
Revised: 7/21/97
Written By: M. Adams
Reviewed By: MEB
Task: Start up Electric Deep Well Pumps.

1. 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.
63
Job Safety Analysis
Date: 0/14/92
Revised: 2/9/93
Written By: C Walker
Reviewed By: MEB
Task: Put Feed Water Heater in service.

1. Go to feed water heater platform, close drain Tripping hazards. Keep stairway clear of debris.
valve.
2. Open block valves to level control 100%. Hand injuries. Wear gloves.
3. Open valve at bottom of feedwater heater to Hand injuries, rust falling from chain operator. Wear gloves , wear goggles.
suction of pumps 100%.
4. Start treated water pump. None. None.
5. Have chief open auto level control valve and None. None.
fill feed water heater to proper level.
6. Valve in 5# steam valve to feed water heater. Thermal burns, hand injuries. Wear gloves.
64
Job Safety Analysis
Date: 9/13/92
Revised: 7/21/97
Reviewed By:
Task: Clean Cooling Tower Screens.

1. 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 Same as 3. Same as 3.
water.
5. Move screen to sump and lower it into Same as 3. Same as 3.
position with hoist.
6. Put grating back over the screen. Same as 1. Same as 1.
65
Job Safety Analysis
Date: 9/14/92
Revised: 7/21/97
Written By: C. Walker
Reviewed By: MEB
Task: Put Fin/ Fan Condenser in Service.

1. Valve in condensate pumps, and turn switches Hand injuries. Thermal burns. Wear gloves.
to auto.
2. Open valve to automatic steam valve. Same as 1. Same as 1.
3. Put switches to fans in auto. None. None.
66
Job Safety Analysis
Date: 9/14/92
Revised: 7/21/97
Written By: M. Adams
Reviewed By: MEB
Task: Obtain Boiler Water Samples.

1. 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.
67
Job Safety Analysis
Date: 2/12/90
Revised: 7/22/97
Written By: GGR
Reviewed By: MEB
Task: Dip Acid Storage Tanks.

1. 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 Wear rubber gloves, rinse tape and float thoroughly
float. with water.
68
Job Safety Analysis
Date: 8/10/89
Revised: 7/21/97
Written By: Walker/ Bussell
Reviewed By: MEB
Task: Sulfuric Storage Tanks: Cleaning procedures.

1. Check to make sure JSA for securing tank has Acid leaks. Be alert for leaks. Locate safety showers.
been followed.
2. Position attendant outside of tank to be Hose failure. Check hose connections.
entered, with a ¾ water hose running,
3. Obtain temperature reading inside of tank Acid inside tank. Wear acid jacket, face shield, goggles, rubber boots
from manway. and gloves, while obtaining temperture from
manway.
4. If temperature is 95 deg. F. or less, enter tank Acid inside tank. Heat and fumes. Slippery floor. Wear full acid suit, face shield, goggles, rubber
and run a sniff test. If above 95 Deg F. contact gloves and boots. Respirators must also be worn be
supervision. careful when walking across tank.
5. Using squeegees, remove remaining acid from Same as 3. Same as 3.
the 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.
69
Job Safety Analysis
Date: 8/10/89
Revised: 7/22/97
Written By: Walker/Bussell
Reviewed By: MEB
Task: Prepare Sulfuric Acid Tank for Service After Cleaning.

1. Close drain valve from tank to ditch and blank Burrs on valve handle. Wear gloves.
off.
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 Weight of fan and cover. Use crane. Wear safety harness.
tank.
4. remove blanks from fill lines and replace spool Acid in lines. Wear full acid suit, face shield, goggles, rubber
pieces, and 90’s or 45’s that were removed to gloves and boots.
secure tank.
5.
6.
7.
8. Remove blanks from suction lines to transfer Same as 4. Same as 4.
pumps, and replace spool piece, that was
removed to secure tank.
9. Check level in adjacent tanks to be sure they Same as 4. Same as 4.
are well below overflow lines. Remove blanks
in overflow lines and replace spool piece or 90
that was removed to secure tank.
10. Remove locks and tags from fill valves and Burrs. Wear gloves.
tank discharge valves. To transfer pumps.
70
Job Safety Analysis
Date: 5/22/89
Revised: 7/22/97
Written By: K. Sams
Reviewed By: MEB
Task: Switching Acid Storage Tanks.

1. 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.
71
Job Safety Analysis
Date: 6/3/89
Revised: 9/9/93
Written By: Holcomb
Reviewed By: MEB
Task: Start Up Acid Transfer to Phos-Acid.

1. 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.
72
Job Safety Analysis
Date: 6/3/89
Revised: 7/25/97
Written By: A. Taylor
Reviewed By: MEB
Task: Start up Air Compressors.

1. Open cooling water valves. Slipping, hand injuries, air leaks. Have sure footing. Wear gloves.
2. Push start switch. None. None.
73
Job Safety Analysis
Date: 6/1/89
Revised: 7/10/97
Written By: K. Taylor
Reviewed By: MEB
Task: Dip Sulfur Tanks.

1. Climb stairs to top of sulfur tank. Slipping and falling. Use hand rails.
2. Obtain tank dip by lowering measuring tape Thermal burns. Cut from measuring tape. Wear gloves.
through hole in top of sulfur tank, until float
reaches sulfur level. Read measurement on
tank.
74
Job Safety Analysis
Date: 6/5/86
Revised: 7/14/97
Written By: Rice/Herbolsheimer
Reviewed By: MEB
Task: Start Up Sulfur Pumps.
1. Make sure steam traps are working and sulfur Thermal burns. Wear gloves.
pump 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.
75
Job Safety Analysis
Date: 2/4/90
Revised: 7/14/97
Written By:
Reviewed By: MEB
Task: Dipping Tank Pit.

1. Remove sulfur from rod. Thermal burns. Wear gloves.
2. Place rod in dip hole until it touches bottom of Same as 1. Same as 1.
pit.
3. Take rod out of pit and place against Same as 1. Same as 1.
measuring tape.
76
Job Safety Analysis
Date: 7/24/89
Revised: 7/25/97
Written By: R. Thompson
Reviewed By: MEB
Task: Lock Out Breaker in MCC.

1. 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.
77
Job Safety Analysis
Date: 8/10/89
Revised: 7/22/97
Written By: Walker/Bussell
Reviewed By: MEB
Task: Secure Acid Tank For cleaning.

1. Close lock out and tag both product acid Acid leaks. Wear full acid suit, face shield goggles and rubber
valves to tank. gloves.
2. Close lock out and tag fill valves from truck Same as 1. Same as 1.
unloading stations. Remove unloading hoses.
3. Pump out tank as low as possible using Same as 1. Same as 1.
transfer pump.
4. Stop transfer pump. Same as 1. Same as 1.
5. Close lock out and tag transfer pump suction Same as 1. Same as 1.
valve and adjacent tank isolation valve.
6. Remove blank from drain line and install acid Same as 1. Same as 1.
drain pump at drain valve.
7. Install drain hose from drain pump to another Same as 1. Same as 1.
acid tank.
8. Pump out tank as much as possible with drain Acid leaks, Hose rupture. Wear full acid suit , face shield, goggles and
pump. rubber gloves. Check hose and connections
carefully. Watchman MUST be present any time
drain 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 Acid in hoses. Same as 1.
and remove pump.
11. Open drain valve from tank to ditch. Acid in drain line. Same as 1.
12. Remove spool piece, 90 or 45, between fill Acid in lines. Same as 1.
valves and tank. Install blank on fill line.
13. Remove spool piece between tank and transfer Acid in lines. Same as 1.
78
pump suction. Install blank on pump suction
line.
14. Check that acid levels in adjacent tanks are Acid in lines. Same as 1.
well below over flows. Remove spool piece, or
90 in over flow lines and blank over flow lines
from adjacent tanks.
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.
79

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

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

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: 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

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: 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

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