API- 4. “=< Accident 22 control TechniquesPILOT: ACCIDENT CONTROL TECHNIQUES Introduction Causes of Accidents and Injuries. Individual Action Prevents Accidents . Handling Materials Safely .... Keeping Your Work Place Safe Flammable Materials Can Be Hazardous . Safety Information When Fire Occurs . Preventing and Reporting Tilness Clothing for Safety . Protecting Your Eyes Protecting the Air You Breathe Other Protection .. Fire Prevention Static Electricity... 02.6.2... Tron Sulfide Control of Hazardous Materials Hot Work Furnace Lighting . Fire Fighting Hydrogen Safety Devices Safe Work Procedures Process Area Precautions .... Entering Confined Enclosures Replacing Safeguards . Working on Machinery Controlling Electricity . Using Ladders and Scaffolds .- Storing, Materials and Equipment Hand ‘foo! Safety . Compressed Gas Precautions . Radiation Hazards Hoisting with Care 5 Handling Railroad Cars .. Driving Plant Vehicles ......+. Horseplay Care of Injuries and Tnesves Putting Safety Knowledge to Worket Company ART - FUORI COMMERCIO - Pubblicazione per uso interno della Societa ANIC Centro Stampa ANIC - RavennaRefinery employees have made a major contribution to the outstanding safety performance of the petroleum industry. This achievement has not been the result of chance. It was deliberately planned and attained by refinery people who ap- plied accident contro! techniques to the things that could Produce accidents. To act safely, it is first essential to know what things are unsafe. Then, to make these things safe, it is necessary to find out why they are unsafe and devise protection against the hazards that are involved. With this knowledge, it be- comes possible to develop effective methods for preventing accidents. This program has been developed to present basic knowledge of refinery accident control techniques. As in every other field of human endeavor, knowledge is essential to enable man to act constructively for his own welfare and the wel- fare of others.INSTRUCTIONS. This is « programed learning course. Programed learning gives information in a series of ste called frames. Each frame gives some information and asks you to make use of it, Here is how it works. First, cover the response column at the right with a_mask. Read this frame and use the information it gives to fill in the blank. B A micrometer is an instrument designed to measure in thousandths of an inch. A micrometer is a good tool for measuring very small differences in size. Move the mask down to uncover the word at the right of the frame, If you have filled the blank with that word or a word that means the same, you are ready to go ahead to the next frame. ‘The drawing of a micrometer provides information that will help you fill in the next blanks, OBJECT TO BE MEASURED ANVIL “ue THIMBLE SPINDLE RATCHET CAP FRAME Seven major parts are shown in the drawing, but only the __. and the contact the anvil; spindle object to be measured. 1‘The next frame calls for a choice. propriate word. ircle or underline the ap- Of the two parts that contact the object, only the (anvil/ spindle) moves, spindle A program is a series of frames that work like the ones you have just done: Read the frame. Use the information to fill in the blanks or make a choice. Move the mask down and check the response column. Go on to the next frame. Remember to cover the response column with a mask before you begin each page. ttINTRODUCTION ‘Causes of Accidents ond Injuries 3. 10. Accidents do not happen by themselves—they are by something or someone. ‘There is a______ for every accident. Accidents and injuries may result from: improper attitudes toward safety; lack of safety knowledge; failure to recognize unsafe conditions; performance of unsafe acts. We can’t stop an accident after it has happened, but we can similar accidents in the future by determining the true cause and taking proper action. People must know what kinds of acts or conditions are unsafe before they can avoid them or them from the job. Eliminating acts which may be unsafe may start your Personal campaign of accident Accidents may be caused by your own actions or work habits. Accident prevention (requires/does not require) you to control your actions and habits, When you think about the ways you could cause an accident and you do what is needed to prevent the accident, you are controlling your. or habits. As you control your actions to prevent accidents, you develop safe work habits. ‘The more you develop safe work habits, the more likely you are to avoid Unsafe cause accidents. peratures and high pressures. These materials are safe when they are kept under control. When refinery materials are allowed to get out of control, they become dangerous and may people or damage property. Anything that can cause injuries or damage property by getting out of —— is a hazard. caused cause prevent eliminate prevention requires actions accidents, or injuries work habits injure, or harm control1, 12, 13, 14. 15. 16. 1. 18, 19, 20. 21, 22, Long experience with the forces, processes, equipment, materials, and work operations of a refinery has made it possible to develop ways of doing work that keep people safe from whatever they encounter. Procedures for doing almost every kind of work in the refinery have been developed. If you follow these established procedures (or rules), you are your actions, Work procedures aré established by studying the work, tools, equipment, and materials, as well as past experience and accidents. Work procedures___________ the hazards which can cause accidents. When you follow established procedures, you are (more likely/less likely) to have accidents. ‘Some persons take unnecessary risks or ignore established Procedures in doing their work. ‘They want to do the job as. as they can, They may believe that detailed procedures take more time than any observable risk justifies. The short cut seems to let them ———,the job in less time with — effort. ‘They may take risks or short cuts because no one has Pointed out to them how . — it is to do so. An injured man may not even recognize that his injury was caused by his own unsafe If people don’t follow established procedures in doing a Job, it may be because they do not how easy it is for accidents to result from incorrect actions, Situations that can cause accidents are hazards to safety, You can eliminate most of these safety from your work. But you have to be able to recognize hazards to safety before you can do much to________them. Until you learn to recognize hazards, you may become involved in accidents (quite often/very seldom). You not only may cause to the tools and equipment you are using, but you also may be or injure a fellow worker. 2 hazards, or dangers controlling ' eliminate, or control less likely quick, or fast finish, or do less. dangerous, or unsafe actions, or procedures recognize, or know, or see hazards eliminate quite often damage injured28. An employee may need. _.____._ from his super- visor to recognize hazards where his knowledge of the Job is not enough to prevent accidents. 24. An employee trained to recognize hazards is one of the best means the company has to. cidents. 25. An employee trained to recognize hazards develops work which enable him to recognize and eliminate these hazards. 26. A safe worker takes time to look for possible hazards in thie job he is about to perform. He can prevent accidents if he makes sure that he recognizes and eliminates all hazards which cause accidents ______he starts the job. 27. The company is concerned about the safety of its employees. ‘The company believes that there is nothing so im- portant as a______employee. 28. The company also believes that its primary safety objective is to injuries to people. 29. By learning to recognize hazards and by taking action to avoid or eliminate them, you might save your own or that of a worker. 30. Each employee needs to know that his own safety de- pends largely on his own actions and the actions of others. He must join in a team effort with his supervisor and his fellow workers to _____ accidents. 31. The company wants your help to insure safe working conditions for all employees. You can help provide safe working conditions by re- porting to your supervisor any, tions you meet or see. INDIVIDUAL ACTION PREVENTS ACCIDENTS \ 82. A situation is unsafe where there is risk of —____. to you or other persons, or risk of —to property. yy 33. Safety, then, is eliminating or avoiding -\ in your work area or work procedures. 3 help, or assistance prevent, or eliminate, or reduce habits before safe, or healthy prevent life; fellow prevent, or unsafe injury damage hazards34. A ladder lying across a pathway (is/is not) a hazard to persons using the pathway. It is not difficult to__________the ladder as a hazard. 35. Once you recognize a hazard like this, you act safely when you take action to_________it or have it 36. To pievent the , search out and- eliminate 37. Tools and materials left lying on platforms or walk- ways are_____. Anyone using the platforms or walkways might trip over them and 38. If you remove these tools, materials, or other objects, it is safer for everyone. If for some reason you can’t remove the objects your- self, then you should immediately____________ the hazards to your_________so that he can have them removed. 39. To be safe is to be alert at all times to the “tripping,” falling,” and “slipping’ and to take whatever immediate action is necessary to see that they are. 40. Tripping, falling, and slipping hazards can best be pre- vented by (good housekeeping/safety signs) through- out your entire work area. 41, Sweeping floors and cleaning up spilled materials which may cause someone to slip (are/are not) a part of ‘good housekeeping. 42. Picking up tools and equipment and putting them away at the end of a job is part of normal good-housekeeping Practice, and it is an important part of everyone's 43. If you find leaks of any kind, you should fix them or them. 44. A leaking fluid may: give off harmful fumes; be a fire hazard; or cause the surface on which it collects to become creating a hazard to safety for other workers. 45. Any unsafe condition you cannot correct immediately should be reported to your for correc- tion. recognize remove removed accidents, or injuries hazards, or causes hazards fall, or get hurt report supervisor hazards eliminated, or corrected good housekeeping are job report slippery supervisor, or foreman46. 41. 48, 49. 50. 51. 52, 53. 54, 55. 56. Before actually starting work on a job, plan what must be done to make it completely safe. First, look for and are present, and then take the sary to prevent an accident from happening. any hazards that neces If you are not sure that you can 0) the hazards that may be present in your job or your area, ask your supervisor what hazards are involved before you start work. Before you start the work, be sure you have all the personal protective__________ that you will need on the job. If you walk through the plant and do not notice where you are going, you may walk right into something, or into the path of a moving object, and be injured before you know it. Just as when you are walking in a city, you should keep your mind______ when walking in the refinery. If you get in the way of other people's work, you may be__________ by their actions or cause them to be by your actions. Sometimes accidents that almost happen reveal — conditions that need correction. For example, a man walks across the shop floor, slips on an oil slick, but manages to keep his balance. He should clean up the spill himself or report it so that the floor may be_______ to prevent some- one else from getting hurt. Suppose a steam line springs a leak directly across a pathway, If you see it, block off the pathway and report the leak so that it can be to prevent someone from getting Inspect the area around you for unsafe conditions, and — your tools and equipment before you them. start to If any tool or equipment is new to you, ask your super- visor to show you the correct way to it before beginning the job. Making sure you know how to use equipment may take extra time, but may__________ you much more time later by preventing an accident. 5 recognize, or identify, or find actions, or precaution: or steps recognize, or identify equipment, or clothing alert, or attentive cleaned corrected, or fixed burned, or injured inspect, use operate, or use save 8,Handling Materials Safely 57, Employees who load or unload vehicles are often in- jured because they lift too much or lift loads with their bodies in the wrong position. If any object is too heavy for you to lift, get someone to ..________ you or use mechanical equipment. 58. When you lift or carry any object, pay particular at- tention to the ____ of your body. 59. Your spine and back muscles were not made for li ing. Your leg muscles were. KEEP THIS LINE NEARLY VERTICAL To lift a heavy object, squat down and get a firm grip on the object, keep your back straight with your feet close together, and by straightening your legs. Always lift with your leg muscles, never with your muscles. 60. Twisting while lifting, bending at the waist, stretch- ing to lift, or changing grip while holding the load are actions that may cause injury to your 61. Positions and motions that require excessive muscle strain may lead to serious 6 help; lifting, or hoisting position litt back back injury62. 65. 66. 67. ‘These two men are lifting objects. Worker (A/B) is less likely to suffer injury because he is lifting with - muscles, If the object he is lifting is too heavy, neither worker is protected from injury by his body position. When ain object is too heavy for you to lift easily, get someone to you, or use mechanical equipment. Lifting long objects and objects that bend calls for the help of other people and special handling. ‘You should have enough other people to help you and be sure there is enough clearance when you or_______long or weak objects, Safe handling procedures will help you avoid striking someone when you carry pipes, planks, or similar long objects past a blind corner. WRONG RIGHT The front end of the object should be (raised above/ level with) your head. When handling materials, protect your hands by wear- ing Safety shoes with steel caps help to keep falling, roll- ing, or moving objects from injuring your 7 Teg help lifting, or hoisting lift carry raised above gloves toes, or feetKeeping Your Work Place Safe 68. 69. 10. n. R. 73, 14. 1. If you take short cuts, you may not always get there safely. ‘You can prevent an accident by using the walkways or pathways that were —__ — for you to walk on, Walking on a transite roof instead of walking on a regular is asking for an accident. Pipelines, tank tops, and roofs may support the weight of a man, but they are not built to be walkways. To avoid injury when moving from one high place to another, use the _______ provided. A hazard anywhere in the plant may be ag_____ to you where you work as it is to the people who work near it, Fires, for instance, can be caused by poor housekeep- ing and poor cleanup after a job. Poor housekeeping can create fire hazards. Dirty clean- ing rags left around in piles instead of stored in the Proper containers are a source of fuel for : An oil spill that is not cleaned up at once may serve as fuel for the spread of a + once it gets started, Besides feeding a fire, an oil spill is a slipping hazard that can lead to Cleaning up an oil spill or covering it with oil ab- sorbent may both a slipping hazard and a fire hazard. Poor housekeeping can create other hazards. Which of these could be a hazard? Yes No Tools and equipment left lying around —___ Hoses or electric extension cords draped over walkways — — Ladders left on the job after use = ___ Pools of water allowed to remain near electrical equipment ee Supplies or replacement parts stacked 80 as to obstruct walkways | Desk or cabinet drawers left open = ____ 8 designed, or built walkway, or pathway walkways, or ladders unsafe, or dangerous fires fire falls, or injury prevent, or eliminate Yes Yes Yes YesFlammable Materials Can Be Hazardous 16. 11. 8. “ 80, 81. In the plant you may encounter petroleum vapors or dust particles. In small amounts, most petroleum vapors (are/are not) dangerous to breathe. Breathing small amounts of petroleum vapors for long periods may cause a form of intoxication. When there is a heavy concentration of petroleum vapors or dust particles, prolonged breathing of these materials may also produce some effects ‘on your body. If you find the air getting full of petroleum vapors or other gases, get out of the area to fresh air at once. Do not _. to the area until it has been approved for re-entry, or until you are wearing ap- Proved protective equipment. Areas that might have concentrations of toxic gases are quite often marked by special signs. DANGER HYDROGEN SULFIDE WEAR YOUR MASK ‘These signs warn you of dangerous conditions that may require the use of — protection, Pay particular attention to signs marked “. a because they are posted to you. A material must be in the form of a vapor (gas) be- fore it can burn. Petroleum products are classed as either combustible or flammable depending on how easily they form vapors. A combustible material is one that will burn only when it is heated enough by a source of ignition (flame, spark, hot surface) to form vapors. A candle is made of a material, A flammable material is one that needs very little or no heat from a source of ignition to form vapor. It catches fire easily and burns rapidly. Gasoline is a highly _______ material. When highly flammable petroleum products are acci- dentally released, they create a serious hazard, are not serious, or toxic, or poisonous return breathing danger, or warning, or caution protect, or warn combustible flammable fireSAFETY INFORMATION 84, 85. 86, 87. 88. 89. Watch for notices on the bulletin boards and poster boards, and read the log books for information on con- ditions that might be — When you see or hear safety information, pass the word on to your fellow workers. Everybody's efforts will help to provide complete plant Warn your fellow employees about hazards they might encounter in their work, and help the new man on the job to avoid danger. . A new man cannot always__________ many of the hazards of the job. Show a new employee some of the less obvious haz- ards in his area, and explain how to recognize and them, If you notice visitors making informal tours (guided or not), help them by alerting them to any they may encounter. Visitors may wander into locations where they might be injured. You (should/should not) tell them about the hazards in these locations and how to avoid them. When Fire Occurs 90. 91. 92, 93, 94, If you see a fire that is fed by a leak, and you are the operator of the equipment, your most important duty is to the flow of oil to the fire. If the fire is fed by LPG (liquefied petroleum gas), avoid extinguishing it until the flow of LPG has been Otherwise a vapor cloud will form which may reignite and If you can properly control and extinguish the fire with extinguishers or other available equipment, use them to put out the fire. If for any reason you doubt that you can control the fire, turn in an at once. If you turn in an alarm, be prepared to fire fighters to the source of the fire. When a fire alarm sounds, determine where the fire is and stay out of the area unless you are assigned to bea 10 dangerous, or hazardous safety know, or recognize avoid, or eliminate hazards should stop stopped, or shut off explode, or flash alarm direct fire fighterPreventing and Reporting Iliness 95. 96. 97. ‘The best way to prevent skin irritations from expo- sure to substances in the refinery is to keep your skin A prompt, thorough, frequent cleaning with soap and warm water will do much to prevent irritations, Any time you are sick while at work, to your supervisor immediately. Clothing for Safety 98, 99. 100. 101. 102. 103. 104. 105. 106. 107. The kind of clothing a man wears (often/seldom) makes the difference between being “safe” and “unsafe.” ‘The company provides personal protective equipment to be worn by each employee to make his work Such safeguards as goggles, gloves, safety helmets, and face shields —. you from many hazards which cannot be____"_ from the work. ‘These protective items protect you only if you____ them. If these items are not in good working condition, they cannot — you properly. If you are assigned a job and find that the protective equipment you will need is not readily available, ask your —__ for it. Certain personal items which you may be wearing can Present hazards on some jobs or in some locations. Rings, chains, neckties, or loose clothing can get caught by objects and severe injury. Study your work area, your work procedures, your equipment, and your clothing before you start any job So that you can be sure your clothing is for the job, A person who wears long neckties and loose or ragged clothing around rotating or moving machinery is al- most sure to have an — sooner or later. Long-sleeved shirts with sleeves rolled down and cuffs fastened give (more/less) protection to your arms than short-sleeved shirts, u clean skin report often safe, or safer protect eliminated use, or wear protect supervisor, or foreman cause safe, or correct accident more108. Where hot equipment, oils, chemicals, and steam are common, the added _. of long sleeves may make the difference between injury and safety. 109. If oils, chemicals, or paints saturate your clothes, take them off at once and put on clean clothing. Clothing saturated with combustibles makes you a walk- ing hazard. 110. Oils, chemicals, and paints may also cause severe skin irritation if they are allowed to in con- tact with the skin too long. 111. When you change clothes to eliminate the fire hazard, wash yourself thoroughly where your skin was in con tact with the materials. By washing, you also prevent skin 112, Some fluids, such as acids and causties, are so injurious that you must rush right into a shower without stop- ping to pull off your clothe: Know where to find the emergency________ fa when you need it. 12 protection fire remain, or stay irritation shower113. Wear your safety hat. The safety hat is the part of your work clothing that protects your —_. from serious injury. 114. Because the safety hat is for your protection, it should be worn (at all times/only part of the time) when you are: inside the plant. Protecting Your Eyes 118. Under “normal” conditions, when you are in offices, control rooms, or locker rooms, you may not be re- quired to protect your eyes. But, when you are out in any other areas of the plant, you should wear the proper type of protection. 116. Some types of work, like welding or chipping, require ———_____ protection for your eyes than safety glasses will provide. 117. Impact or cover-all goggles and welder’s or chipper’s goggles give extra protection against flying materials, dirt particles, and intense glare. COVER-ALL GOGGLES WELDER'S GOGGLES When you are buffing, grinding, or hammering, your eyes are better protected by (safety glasses/special goggles). 13 head at all times more, or greater special goggles118. Chemical-type goggles protect eyes against the special hazards of working with, or near, equipment containing acids, caustics, or other corrosive or harmful ___. CHEMICAL-TYPE GOGGLES out of your These goggles keep the 119. A face shield or a welding hood protects your face and eyes from injurious chemical splashes, glare, or heat, WELDING Hoops FACE SHIELDS) Wear a shield or’ hood: when you are welding; when you are opening cover plates of furnaces to in- spect them; when you are opening chemical lines containing acid or zi 4 chemicals, or materials chemicals eyes caustic120, 121. 122, 123. 124, You must choose the right type of special, additional eye = ——impact or cover-all goggles, chemical- type goggles, or a face shield—when you do work that is extra hazardous to the ‘and Grinding, buffing, using jackhammers, and working where rust or other foreign materials may fly up create serious eye hazards. Use__________.______ goggles to protect When working on pressurized equipment, opening vents and drains, or drawing samples of products or chemicals, it is best to use = - goggles. For opening acid or caustic equipment, sampling hot products, and handling hot metals, protect yourself addi- tionally by wearing a shield. ‘When you are handling catalysts or powdered materials, or working where there is dust in the air, you need to have special protection for your eyes and face. If there is enough dust to be harmful, you also need to have breathing protection to keep dust out of your Protecting the Air You Breathe 125. 126. 127, Hot air may injure your nose, throat, and lungs. When the air you breathe is hotter than 140° F, you must wear equipment that protects your lungs and Passages. If you enter or work in an atmosphere known or sus- ected to contain harmful concentrations of gas, vapor, or mist, wear the proper protection provided. Use the right protective equipment for the job. If you don’t have the tion to use, ask your supervisor. breathing protec- 15 protection eyes; face impact-type, or cover-all chemical-type face lungs, or throat, or nose breathing breathing Proper, or correct,128, 129. 130. 131. 132. In some situations, normal work conditions create extra hazards for breathing. SELF-CONTAINED AIR SUPPLY In these situations you must have extra protection against these hazards, to prevent your nose, throat, and from being damaged. Crude oils contain sulfur compounds. Refining proc- esses change these sulfur compounds to hydrogen sul- fide (H,S), a very toxic (poisonous) gas that is car- ried through many of the product streams. Hydrogen sulfide is very to breathe. Very small amounts of H,S in the air have a putrid odor like rotten eggs. But dangerous amounts cannot be detected by odor since these amounts paralyze your sense of, Concentrated H,S can be very harmful, causing uncon- sciousness and possible Because of its odor, H.S is often called “foul gas” or “sour gas. ‘You must always wear proper Protec- tion where H,S could be present or could be released your work area, 16 lungs dangerous smell death breathing133, 134, 135. 136. 137, 138. 139. Vessels that collect water (condensate drums) in many processing areas often contain unsafe amounts of H,S. When the water is drained or drawn off, a dangerous concentration of H,S gas may be at the “draw off” line. Other sources of H,S are “foul condensate” accumu- ators and strippers, foul gas burning lines, amine and caustic absorber systems, and pumps connected to such equipment. ‘Sampling, opening lines, vessels, or pumps, or similar work with these sources of H,S gas must be done care- fully to protect against the _— created by the release of hydrogen sulfide. If you smell H.S in a processing area, get out of the area to fresh air immediately, and__________ the condition to the people in charge. An extremely dangerous hazard is an accumulation of HS in sour crude oil storage tanks. Any time you are inspecting, gaging, drawing samples, repairing sour crude containers, or descending to the floating roof of a tank of sour crude, you must wear approved ________ protection. Another gas capable of causing unconsciousness and death is carbon monoxide (CO), an odorless gas that is formed by the incomplete burning of fuels. CO (can/eannot) be detected by a sense of smell. Carbon monoxide is present in the stack gases of all furnaces, gasoline engine exhausts, cat-cracker regen- erators and their flue gas ducts, CO furnace fuel lines, and in the spent cat-cracker catalyst contained in re- generators and storage vessels, You must wear approved protection where CO can be present in unsafe amounts. Several toxic gases may be present in vessels that have been opened after being cleaned with acid. Breathing protection must be worn to enter these ves- sels unless approval is given to enter breathing protection. WwW released, or present hazard report breathing cannot breathing without140. 141. 142, 143. 144, 145, You need some breathing protection during spray paint- ing and similar operations that put small particles into the air. When you are sandblasting, an air hood specifically designed for this work (is required/is not needed) for proper breathing protection. An atmosphere which contains more than 500 parts per million of hydrocarbon vapors (1 part vapors to 2000 parts air) creates a hazard which requires proper A test is necessary to determine whether an_____ amount of hydrocarbon vapor is present, Since the lapse of time or the nature of the work being done in a vessel may permit gas-bearing deposits to release hydrocarbon gases, it may be necessary to ——— again each day or at the beginning of each shift, ‘When there is not enough oxygen in the air to supply all of the body’s needs, an oxygen deficiency is present. Some gases that are not flammable, toxic, or irritating, such as nitrogen and carbon dioxide, can be harmful when they displace some of the SBRRBE ini tie) atmosphere of a confined enclosure (vessel, well, con- duit, deep excavation, ete.). Death by asphyxiation may result when there is not enough oxygen in the air you Oxygen deficiency may be a serious hazard in certain confined enclosures that are not properly ventilated or that have contained nitrogen or__________ dioxide. If you know or suspect an unventilated location of having deficiency of oxygen, you must not enter it without breathing equipment that air or oxygen. 18 is required breathing protection, or breathing equipment unsafe, or harmful test oxygen breathe carbon furnishes, or provides, or suppliesOther Protection 146. Safety hats, eye protection, and breathing protection equipment are items of personal protective equipment for your_______._ at work. protection, or safety 147. Special skin-protection creams, heat-resistant clothing, I foot guards, and numerous hoods and head coverings are also designed to protect you while you are working at any job that may be extra______. hazardous, or dangerous 148. Rubber gloves, asbestos gloves, and other gloves; safety belts and auto safety belts; and chemical clothes are additional sources of protection. When you are in a situation where you can ___ recognize the presence of a hazard and you don't quite know which equipment is the best protection against the hazard, ____ your supervisor. ask 149. Report all unsafe personal protective equipment to your supervisor. ‘When you depend upon personal protective equipment that is not in good condition, you take the kind of that leads to injury. chance, or risk FIRE PREVENTION 150. Fire prevention is the major concern of (the plant manager/the fire fighters/everyone in the plant). everyone in the plant 151. Fire occurs when a fuel and a source of ignition (heat) are brought together with a sufficient amount of air or oxygen, If one of the three essentials in the “Fire Triangle” is missing, fire (can/eannot) occur. cannot 152. The purpose of fire prevention is to keep these three elements of fire—fuel, ___, and a source of air, or oxygen from coming together. ignition, or heat 19153. 154, 156. 156, 187. 158. 159, 160. 161. 162. Because of the severe fire hazard, smoking (is per- mitted/is not permitted) within the plant, except in designated areas. “Strike anywhere” household matches should never be brought into the plant. ‘These matches are easily________by friction, even while in your pocket. If flammable _______is present, the match can. become a source of _. A lighter with an exposed trigger or striking wheel can produce ________ when it is dropped. Such an unsafe lighter can be a source of ignition, where____ gas is present. A lighter that can be triggered by accident should not be brought into the —____, Cigarette lighters of the closed type may be brought into the plant because they cannot produce by themselves. A welding torch lighter may be ignited accidentally when it is closed. A welding torch lighter is always carried in ( a closed/ an open) position. Solvents to be used as cleaning fluids must meet cer- tain flammability requirements to be considered safe for use. Flash point is the temperature at which a liquid fuel forms enough vapor to “flash” into fire when a source of ignition (heat) is present. A solvent with too low a flash point is The minimum acceptable flash point for general- purpose cleaning solvents is ordinarily set at some point between 100°F and 150°F. You should learn and always observe the acceptable minimum — —_______ established by your plant. ‘When you find it necessary to change from one solvent to another, obtain the of your super- visor before changing. 20 is not permitted ignited gas ignition sparks flammable plant sparks an open dangerous flash point approval, or permission163. 164, Almost any kind of cleaning solvent causes irritation of the skin by removing the skin’s natural __ To protect your skin from irritation: and dryness, (never/sometimes) use gasoline or naphtha to clean your hands or other parts of your body. Static Electricity 165. 166. 167. 168. 169. 170. Iron 11. 172. The flow of fluids such as air, steam, gases, and liquids generates charges of static electricity. These charges build up as flow continues. When these electrical charges build up high enough, a spark_________ from the fluid to the nearest object. When the is hot enough, it can ignite a flammable gas mixture that may be present and cause a______or explosion. Flammable products being loaded into any kind of con- tainer build up a charge of in both the product and the container. Static electricity sparks can_________ flammable mixtures of fuel and air that may be present in the container. When you transfer or pour petroleum products from one container to another, attach the grounding devices Provided to static electricity from sparking. Unless this charge is electrically grounded, sparks jumping the gap between the container and the filler hose may________the flammable materials. Sulfide Iron sulfide is a substance resembling rust, except that it is coarser and darker. Iron sulfide is formed by the chemical reaction of sulfur-bearing oil with iron surfaces. When iron sulfide is________to air, it dries out. When iron sulfide dries out, it heats up and catches fire spontaneously, Combustible materials which come into contact with the burning iron sulfide may be by the heat. 21 oils never jumps, or crosses spark fire static electricity ignite prevent ignite, or light exposed, or opened ignited173. Any area where iron sulfide is known or suspected to be present should be wetted thoroughly with water before attempting to____ the sulfide. 174, When iron sulfide is being removed from piping or from vessels during cleaning operations, the iron sulfide must be kept to prevent ignition. 175. When there is iron sulfide in an area where hydrocarbon vapors may be present, the iron sulfide must be kept constantly 5 176. The iron sulfide must be removed immediately to pre- vent it from igniting and possibly causing a_____. 177. Even when there is no emergency reason for removing iron sulfide, it should always be taken to a—__ place and burned under controlled conditions or buried in the ground. Control of Hazardous Materials 178. When equipment is opened for cleaning or repairs, hazardous materials such as hot, corrosive, toxic, or flammable liquids or gases must not be released into or from the equipment. Before you open piping or equipment for any purpose, you must take precautions to prevent th of any hazardous materials they may contain. 179. Besides exposing yourself to toxic gases, you may re- lease flammable vapors and cause a—______or an 180. If the materials are hot, someone may be seriously as they are released. 181. Or, if the materials are corrosive, they can cause severe ________ to people and ____ to ‘equipment. 182. When block valves are used to stop the flow before breaking a line or opening equipment, each of these block valves should be chained.and locked or tagged in its position until the job is completed. 22 remove wetted, or wet wet fire, or explosion safe release fire ‘explosion burned injuries, or burns; damage closed183. 184, 185. 186, If chains and locks are not used to secure the valve in the closed position, close the valve securely and then attach a “DO NOT OPEN” tag to the wheel of the valve so that it can be seen in the operating position. Anyone who might start to open the valve would then see and obey the “ ee tag. A double set of block valves with a bleeder valve be- tween them is sometimes used. If one of the block valves leaks, the leakage will be evident at the valve, To keep flammable materials away from sources of ignition in equipment which has been opened, always blank off (blind) or _ lines that connect with sources of flammable materials, A vessel or equipment that is to be entered or worked on should be similarly _. — or to protect personnel from corrosive chemicals, hot liquids, or hazardous atmospheres. Hot Work 187. There are times when welding must be done on equip- ment. Welding is called hot work and requires a hot-work permit because of the high — it produces, and the resulting danger of igniting hydrocarbons, 23 DO NOT OPEN bleeder disconnect blanked, or blinded; disconnected temperature, or heat188, 189. 190. 191, 192, 193, 194. 195. Any work using tools or equipment that produce hot sparks, or using flame or high temperature, requires permit before the work can be started. Whenever hot work is to be done on any equipment that is connected to sources of flammable materials, all connecting lines should be either blanked off or disconnected. Blanking and disconnecting are the safest methods for preventing the release of flammable materials in a sepeastantel \cestion’ Sandblasting and grinding produce heat and sparks. Because hot sparks may be sources of ignition, spark- producing work may also require a hot-work permit you start a job. Exhaust from internal combustion engines, and sparks from nonexplosion-proof motors driving portable pumps and compressors may also create ___ hazards in areas where flammable vapors are present. When you operate portable engines, pumps, or com- Pressors in areas where flammable vapors could be present, you should have a hot-work permit in your Whenever you are not sure whether a hot-work permit is required to do any work, ask your before beginning, Hot-work permits are not required in such places as maintenance shops where is a normal part of the daily work. ‘Vehicles may be required to have a hot-work _ to enter certain restricted areas in the plant. g§ernace Lighting 196. 197. 198, Lighting furnace burners can be a very dangerous operation unless it is done correctly. You must follow definite procedures and precautions to_________the hazard of flammable vapors in fireboxes and stacks. ‘The process of removing flammable — — from furnace fireboxes and stacks is called “purging.” Any furnace which is to be lighted or relighted must first_be purged to remove all flammable vapor from the firebox and stack before starting to_____ the burners, 24 hot-work hot-work before fire hand, or possession supervisor hot work permit eliminate vapors light, or ignite ‘Now turn the page, turn the book ov and 90 on.199, 200. 201. 202. 203, 204. 205. 206. Fire 207. 208, 209. Usually steam is used to__________natural draft furnaces. Usually, air is used to purge forced draft — Make a thorough visual check of all furnaces to see that combustible materials such as oil, wood, and rags have been_______ from the firebox before lighting any burners. Finally, a combustible gas indicator can be used to check appropriate points in the firebox before any burners. After thorough purging for removal of flammables, put on a face shield over your safety glasses and be sure to wear your gloves. ‘While you are lighting the furnace burners, the face shield is your protection again flashing back into your face. Use only a regulation torch or indi light the burners. idual burner pilot to If the burner has a pilot, always light (the burner from its pilot/the pilot and the burner together with a torch). Do not light one burner from another. Lighting each burner with a torch or with its pilot__________ the chance of flashback. Fires and explosions have occurred during the lighting- off of furnace because safe procedures were not followed. Fighting ‘The success of the total fire prevention program depends upon everyone's constant vigilance. Once a fire has started, the plant's own fire-fighting equip- ment and its own crews may be the only means available (ca seceennrEE Uh fires If you are a member of an assigned fire-fighting crew, you may take part in fires. The company wants no fires, and it wants you to take every precaution to recognize fire hazards and a fire from starting. 25 purge furnaces removed lighting flames, or fire the burner from its pilot reduces, or lowers burners fight, or control, or extinguish fighting prevent.210. Fire hose, extinguishers, reels, nozzles, monitors, and such are for emergency fire-fighting only. Protect fire-fighting equipment in your area. It is there to protect both you and the equipment from —— hazards. 211. Be sure that fire-fighting equipment (nozzles, extin- guishers, reels, hydrants, monitors, hose) is kept visi- ble and free of obstructions at all times. If you need to discharge an extinguisher either par- tially or completely for any reason, report your use of the extinguisher to your _______ immediately. 212. Your prompt reporting allows prompt replacement of the used extinguisher with a __________ extin- guisher. Hydrogen 218. Hydrogen is an extremely light and flammable gas that is very easily ignited by sources of low energy. Hydrogen burns with a pale blue, almost colorless flame that is nearly invisible in daylight. Since hydrogen is so light, it can escape from piping joints much (more/less) readily than heavier gases. 214, When you are in an area where hydrogen is present equipment, you will be especially alert in approach- ing piping and equipment joints, since the greater the percentage of hydrogen the (easier/harder) it is to see a burning jet of gas. 215. If you detect a leakage of hydrogen, either ignited or unignited, __________the location of the leak to the people in charge. SAFETY DEVICES 216. Wearing the right protective equipment (protects/ does not always protect) you from accidents caused by defective or malfunctioning machinery. 217. Steam turbines are high-speed machines that require safety devices to prevent them from overspeeding and flying to pieces when a load is suddenly removed. The steam turbine is equipped with a safety device (overspeed trip) that eee the turbine when a maximum safe speed is reached. 218. If the overspeed trip fails to function, the turbine could fly to pieces and__________or kill people and cause great property 26 fire supervisor, or foreman full, or recharged, or new more harder report does not always protect shuts down, or shuts off injure damage219. This accident would not be of your making—it could happen because a safety device failed to the way it was designed to work. 220. So, to be safe, check the safety devices on your equip- ment before you operate the equipment, to be sure that they — ———— properly at all times. 221, Safety devices are put on equipment to protect you from injury. Alarms and other warning devices are to alert you that operations are upset and may become 222, But some people may ______ the safety device, or make it inoperative. 228. Every time you remove, block off, or otherwise render a safety device inoperative, you remove its means to protect or _________you and others before an accident happens. Lives depend upon safety devices that properly. 224, If a safety device cannot be adjusted or repaired by an authorized person while it is in service, attach an “OUT OF SERVICE” tag to the device and your supervisor immediately. 225. Once the safety device has been tagged “OUT OF SER- VICE,” follow the instructions of your : SAFE WORK PROCEDURES Process Area Precautions 226. If your work takes you into a process area, you should secure the of the supervisor or opera- tor in charge of the area to enter. 227, The operator in charge of a process area is responsible for providing safe working conditions for (anyone in his area/only his own crew). 228. You should get approval from the operator in charge you start to work. 229. For example, when furnace tubes are being opened, the first plug on a furnace should be pulled by the operator in charge or by someone in his presence. ‘You must have the____of the operator in charge before you can begin your part of the opening operations. 27 function, or work work, or operate, or function hazardous, or unsafe ignore, or remove warn work, or operate inform, or notify, or tell supervisor approval, or permission anyone in his area before approval230. Any valves or controls that need opening or closing can be only after the operator in charge has given his permission. 231. Never turn electricity, gas, steam, air, chemical, or water lines on or off until the in charge has indicated it is safe to do so and has given his permission. Entering Confined Enclosures 232. Even after you have permission from the operator in charge to operate valves, controls, or machinery, you must check before you start to see that no one is in a position to be by your actions, 233. Entering confined enclosures, such as vessels, tanks, fur- naces, or manholes, requires the approval of the operator in charge before the enclosure may be for any purpose. 234. Even if you have permission of the operator in charge, do not enter a confined enclosure without following al local rules for entry, such as requirements for tags on points of entry and checking in and out with a designated Person. Be sure you know what is required in the way of pro- tective and equipment to guard against hazardous chemicals or atmospheres, 235. If a vessel or confined enclosure (sewer, electrical conduit duct, sump, or deep pit) is being opened for the first time, it should be tested before entering to make sure there is no deficiency of _________ for safe breathing. 236. Even if the confined enclosure has been opened before, it may still be advisable to make a test for oxygen de- ficiency to ensure a atmosphere. 237. Any time a test shows a deficiency of oxygen in the at- mosphere in an enclosure to be entered, stay out unless you have proper Protection. 238. Even if the supervisor in charge determines that there is no chance of an emergency which would hinder your safe exit from the confined enclosure, you should alert another person to keep the general area under 28 operated operator hurt, or injured entered clothing; breathing oxygen, or air safe breathing observation, or surveillance239, 240. 241. 242. 243, This alerted outside person should be prepared to render aid in an emergency and give warning to others of what they are likely to encounter in the confined enclosure. Even if the supervisor in charge determines that there is no chance for an emergency to block your safe exit from the confined enclosure, someone in the area should be aware of your entry. When a breathing hazard can develop in a confined enclosure, the alerted person outside the vessel should have proper protection at hand. When you have to enter an enclosure where gas or other hazardous materials are present or may be liber- ated during work, the precautions you must take are determined by your ‘Your supervisor indicates the type of breathing pro- tection you need, the procedures you must follow, and the kind of equipment that you need for your Tanks and other vessels that have contained TETRA- ETHYL LEAD must never be under any circumstances, unless your entry is approved and observed by specifically authorized persons. Replacing Safeguards 244, 245. 246. 247. As soon as you have finished a job in a process area, you must_________the operator in charge that the work has been completed. If you leave a job where manhole covers, valve pit covers, stairway handrails, or platform sections have been removed, place a guard over the opening to — people moving around the area from falling into the opening. When your work is finished, always check to see that any covers, platforms, stairway guards or handrails which were removed during the work have been replaced. The job is not completed until you have —____ any safeguards that have been removed. If you have installed barricades, signs, signals, or other warning or protective devices, it also is necessary to ——--—___ these to complete the job. 29 dangers, or hazards breathing supervisor protection entered notify, or inform keep, or protect replaced remove248. As long as an excavation or trench is open, it must be covered, barricaded, or roped off (only at night/ whenever you leave the job). whenever you leave the job 249. If you must leave an excavation uncovered overnight, better protection is afforded by (a barricade/a barri- cade and a warning reffector or flasher). a barricade and a warning reflector or flasher 250. When you are digging a trench or hole, check with your when you uncover regular con- supervisor erete, red concrete, piping, or electric power lines. Do not continue to dig until you have received his to continue. OK, or approval, or authorization 251. Some plants require an excavation permit before — starts. digging, or work This better assures that everyone concerned knows what — equipment may be disturbed. underground, or buried 252. Check with your supervisor to find-out what is needed to insure safe digging. If the trench or hole is deep, you may need bracing or shoring to prevent a — 5 cave-in Working on Machinery ‘253. If the guards or shields designed for the equipment or machinery you are about to operate are not in place, do not ___________ the equipment. operate 254. When machinery must be worked on while it is run- ning, you (need/do not need) to plan your work to need include extra precautions to prevent injury. 255. Two situations where work may need to be done while machinery is running are: when it is necessary to belts or align chain drives while in motion following repair; when it is not _ to shut down the ma- possible chinery for oil, cleaning, adjusting, or certain re- pairs because of the need for continuous operation. 256. You must always shut off the power source before you start work on machinery that is shut down for repairs. The power source must be locked out or tagged out to prevent it from being while work is in progress. turned on 30257. 258. 259, 260. 261. 262. 263. Protective devices used to lock out or tag out equipment must not be removed by anyone but authorized persons, Lockout The person authorized to remove such a device is usually the person who it in the first place. No authorized person should remove a lockout or tag- out device until all persons working on the job have completed their work and are in a___ position. Electrical or electrically driven equipment must have its main switch or circuit breaker positively out. To be sure the switch or circuit breaker has actually shut off power to the equipment, always for power before you start to work by operating the “start” button or switeh. If for any reason the switch or breaker can’t be locked out, do not start to — until provisions are made to do the job safely. Machinery which is powered by air, steam, or gas must have the closed block valve protected from accidentally being ___._by having a lock, a locked chain, or a “DO NOT OPEN” tag firmly attached to the valve wheel or plug. If a closed block valve in the supply line leaks through, it (must be/need not be) blinded. 3L installed safe locked, or tagged check, or test work opened must beControlling Electricity 264. 265. 266. 267. 268. 269, 270. am. 272, 278. 274, Using 215. Only authorized persons may connect, disconnect, repair, or adjust electrical equipment. You are an authorized person when repairing the equip- ment is a part of your job. As an operator of electrical equipment you may be au- thorized to__________or repair certain electrical equipment. Replacing a bulb in a live circuit (can/will not) produce a spark. When a vapor-proof or explosion-proof fixture is opened for bulb replacement, its safety features (are/are not) still effective, ‘Thus bulb replacement is safe only when the circuit is + or when there are no flammable Present in the atmosphere. Where explosion proof outlets are provided, use tools and extension cords that are provided with plugs to match the outlets. If tools or extension cords do not have explosion. Proof plugs, the use of a standard plug adapter in an explosion-proof outlet (should be temporary only/can be permanent). Electric hand tools and extension cords should always be equipped with three-wire cables or grounding clamps to Prevent shocks to the user. When you use grounding clamps, attach them securely between the tool and a ground (before you start the tool/ after you have tried the tool once to see if it is working.) Extension lights must have a protective guard around the bulb to prevent the bulb from An extension light used in damp or wet locations must have a molded rubber socket and an approved moisture- Proof cord to prevent to the user. ‘When you use electrical equipment of any kind, study it carefully to determine how to avoid injury, and then take whatever preventive are necessary. Ladders and Scaffolds A simple job of using a ladder can be hazardous unless you the hazards and take measures. 32 assigned adjust, or replace can are not dead, or off gases explosion-proof should be temporary only before you start the tool breaking shock actions, or precautions recognize; preventive, or protective276. Use a ladder that is in good condition, and make sure it is equipped with proper shoes or spurs to prevent 277. When you place the ladder, set its base out one foot for every four feet of length of the ladder. 24 FT. 6FT. ke FT. (Ladder A/Ladder B) is positioned properly. 278. If you are using a straight ladder that extends above the point it is leaning against, never step on the rungs the contact point, because your weight may overbalance it and cause it to fall. 279. When you must set your ladder on an insecure sur- face, tie it or have someone hold it for you. A ladder that is improperly placed or anchored creates a (falling/walking) hazard for you. 280. (Never/Always) use the top half of an extension lad- der by itself as a straight ladder. b 281. (Only one person/Several persons) may work at a time on the same ladder. 282. When you are using a step ladder, (never/always) stand on the top unless it has a working platform. 283. When climbing a ladder, keep both of your hands free for holding onto the ladder. Use a hand line to materials or tools up to you, or to_________ them to the ground. 284. When you have finished work, do not leave your lad- der where it will passageways or oper- ating controls. Take it down and— _—— it properly. slipping Ladder A above falling Never Only one person never raise lower block, or obstruct store287. 288, 289. 290. 291. 292. 293, 294. 295. 296. Scaffolding and work platforms must be properly con- structed for the.______ to be done. Scaffolds and work platforms must be put up so they do not block or obstruct passageways, exits, or oper- ating controls. They must also be located so that they do not —~— access to, or operation of, any fire- fighting equipment. Drums, boxes, pipe nipples, and valves are not to be used as supports for ladders, makeshift or work platforms, Chains, valves, or pipe nipples (are/are not) safe enough to be used as steps for climbing. Before you start to use a scaffold, make sure all planks, whether wood or metal, are_________ 0 they cannot slip off or along their supporting members. To make sure the planks ________ move, cleat them, clamp them, wire them, or nail them before you use the scaffold, As you make sure the planks are fastened down, check to see that all structural parts are in place. If any structural part of a scaffold must be removed so that a particular job can be done, replace it as soon as the job has been Guard rails that are in place and secure before you start working from a seaffold will prevent you from off, When you are working at hazardous heights where a well-guarded work platform cannot be used, you should protect yourself with a safety (belt/hat/glasses). If you wear a safety belt, make sure that the lifeline of the safety belt is firmly to a solid support. Here are some examples where safety belts should be used: when you are working on a suspended scaffold at a hazardous working in a hopper ear to______ mate- rials; or working over a condenser box or sump containing deep or hot ‘When you are working overhead, make sure that per- sons — you are aware of your presence. 34 job, or work block, or obstruct scaffolds are not fastened, or secured can’t, or don’ completed falling belt attached, or anchored height unload, or remove liquids, or materials below, or under297. 298, 300. If you are working above a road, walkway, exit, en- trance, or other place where persons are working or passing below, place a sign at their level to alert them to the hazard overhead. If a warning sign is not sufficient, or if there is great hazard, the danger area should be... off until you are through with the job. Any scaffolding platforms, or roping used (includ- ing safety-belt lifeline), should be dismantled and —— from the work location promptly after the work is completed. After dismantling scaffolds or work platforms, store them so that the parts do not fall or cause other stored materials to Storing Materials and Equipment 301. 302. Materials stacked or piled where they obstruct aisles, walkways, stairs, ladders, exits, or fire-protection equipment are (a nuisance/a hazard to safety). Pipe should be spaced, wedged, and chocked when stored. (Stack A/Stack B) is stacked in the correct and safe way. 35 warning blocked, or roped, or barricaded removed fall a hazard to safety Stack B303. Cross-tied stacking is the safest way to store bags. ‘The bags in (stack A/stack B) are less likely to fall stack B because they have been cross-tied 304. When you stack drums or other large containers, stack them so they cannot topple over and hurt, or injure someone. 305. Combustible materials must never be stored so they hot surfaces like light bulbs, steam touch lines, or furnaces. Hand Tool Safety 306. Chisels and hammers are common hand tools that pre- sent hazards to safety. MUSHROOMED = BATTERED =— SQUARE HEAD HEAD HEAD CHISEL, CHISEL CHISEL yy RADIUS UNSAFE UNSAFE SAFE When struck with a hammer, a (mushroomed head chisel/square head chisel) is more likely to produce mushroomed head chisel flying chips. 307. All tools should be checked (periodically/each time you use them) to make sure they are safe. each time you use them 36308. 309. 310. Bul. 312, 313. 314. 315. Alll defective equipment should be (reported to your supervisor/returned to the proper storage place) so that repair or replacement can be made. Using the wrong tools or equipment on the job is just as as using defective tools or equipment. If you try to use a screwdriver as a punch, a wedge, or a pinch bar, you may cause an accident, because these functions (are/are not) what the screwdriver is to be used for. A pair of pliers used as a wrench “chew up” a nut so badly that a proper sized wrench can (no longer/ easily) fit the nut. As a result, the next time someone applies leverage on the nut with a wrench, the wrench may _ and cause an accident. The use of only one wrong tool can cause an that may result in a severe to you. If you do not have the______tool or equip- ment to do a job, get it from the tool room. Inspect your tools regularly to see when they need a sharper edge, a new handle, a smoother surface, or other care. HAMMER HEAD WEDGED ON HANDLE IN BOTH DIRECTIONS Cutting tools should be hammer heads should be solid and securely —__ on the handle; and burrs and mushrooms should be —__ from hammers, chisels, and the like to prevent pos- sible injury from flying fragments. Compressed Gas Precautions 316. ‘Many plant operations use compressed gases in cyl- inders. ‘These compressed gas cylinders are dangerous, unless handled with proper care, because of the high of the gases stored in them, 37 reported to your supervisor unsafe, or dangerous are not no longer slip accident injury right, or correct sharp wedged removed Pressure317. 318. 319. 320. 321. 322, 323, When compressed gas cylinders break, they act like jet missiles and are likely to cause a lot of Handle gas cylinders gently. Allowing them to drop, bang together, or strike solid objects is extremely Unless you are using the cylinder valves to release gas from compressed gas cylinders, they should have their protective _________on them at all times. By keeping the protective caps on the cylinders when they are not in use, you break the valves off and a serious accident. Compressed gas cylinders should be kept standing up- right during storage or use, SAFETY BRACKET, N\ A cylinder should be secured to a solid support in an up- right position with a chain or Because acetylene cylinders contain a liquid solvent, (always/never) lay an acetylene cylinder on its side, for storing or use. Always remove pressure regulators and piping, and always install protective caps when you compressed gas cylinders from one place to another, even for short distances. 38 damage, or destruction dangerous ‘caps, or covers cannot cause safety bracket never move, or transport324, 325, 327. 328, 329, 330. 331. 332, 833, 334, When compressed oxygen combines with hydrocarbons under certain temperature and pressure conditions, it reacts to cause a fire or explosion, In the plant where oils, grease, and hydrocarbons are likely to be present, ______gas presents an ex- treme hazard, Oxygen must be kept away from all materials. Always check the label or stencil on a compressed gas cylinder to make certain you have the _ gas to be used. . If the eylinder has no label or stencil, or there is no plant test tag attached, do not use it. Report the condition of the cylinder to your Until you definitely : tained in a cylinder, do not use it. the kind of gas con- Welding gas cylinders with hoses and torches attached may be left unattended for more than a few minutes only if the cylinder valves are closed and pressure is released from the hose. Never leave welding gas cylinders unattended for long periods if the hoses are pressurized or if the torches are attached and Before you start to use oxygen and acetylene for welding or burning, make sure that check valves have been in- stalled in either the hoses or the torches to prevent the oxygen and acetylene from .. in the hoses before they reach the torch. Compressed air for general plant use is usually supplied from fixed or portable compressors. You (should/should not) use compressed air to blow dust from clothing, A broom, water hose, or vacuum should be used for floor and deck cleaning. should not be used, ‘The force of compressed air is great enough to imbed small sharp particles of rust or debris in your skin. ‘These particles may cause painful wounds that easily become If you have open wounds on your hands or body, using compressed air to “dust” yourself could force air into a »then into the blood stream, Air forced into your blood stream may cause serious in- jury or even 39 oxygen flammable Proper, or correct, or right supervisor identify, or determine, or know ignited, or burning mixing, or combining should not Compressed air infected wound death835, Particles of iron, wood, and other materials become flying projectiles when they are picked up and blown around by compressed air from your operations. ‘These flying projectiles represent a serious hazard to Persons working close to you unless a screen or other — device is used to shield them. When you are using compressed air, always w face shield or _____..____ even if you are wearing safety glasses, Radiation Hazards 337. 338, 339, 340. 341. Safety precautions must be taken (only by the users/ by anyone in the vicinity) of radiation devices. Because of the hazards involved, the Atomic Energy Commission (AEC) has designed a standard symbol to all persons of the presence of radi tion devices. STANDARD RADIATION WARNING SYMBOL. YeLLow BACKGROUND PURPLE ay When this symbol is displayed, it means that ____ devices are in use, When radiating devices are operating, properly iden- tified barricades with radiation _________ signs must be erected to close off the unsafe area. the devices, into the radia If you are not involved in you must not cross the _ tion area, You must be properly trained and authorized, and must wear a dosimeter or film badge which will show the degree of radiation, before you can — or service any radiation-producing devices. 40 protective, or safety ogee by anyone in the vicinity warn radiation warning operating barricade operateHoisting with Care 842. Hoisting equipment is used extensively to lift, stack, and store materials. Before operating any hoisting equipment, ee inspect, or check it to make sure it is in safe operating condition. 343. Wire strands may be broken on cables, fiber rope may be frayed, chain links may be stretched, or hoist hooks may be bent. Have defective parts repaired or replaced before you the equipment, operate, or use 344. When you are using a hoist, the hoisting area and pést signs to warn others of the danger. rope off, or block off 345. If you are working in a hoisting area, always keep clear of the load while it is _____"_ or moving. suspended 346. Keep your hands off moving rope or cables. If you are responsible for controlling the load, use tag lines to the load where you want guide, or direct it to go. 347. By using tag lines to guide the hoisted load, you —_______getting your hands pinched between avoid the moving load and some stationary object. 348. There is extreme danger for all concerned when a hoist must be operated close enough to electric power to come in with these lines. contact aL349. 351. 382. 353. 854, 355. 356. The safest way to do hoisting around electric power lines is to the power from the lines by locking out the switch or circuit breaker. . Whatever you do, do not stand on the ground and touch or lean against any part of the hoisting equip- ment while it is operating in the vicinity of overhead When hoisting is done, (one man only/everyone) should give signals to the hoist operator. Before the man giving the signals and the operator can work together or_________ with each other, they must both know and use the standard hand sig- nals for hoisting. Every person who may direct lifting operations and every operator of lifting equipment must know and use these standard hoisting .to do the work safely. If you are the man directing the equipment operator, you face (directly toward/directly away from) the operator. Use (only your right hand and arm/either left or right hand and arm) to signal. Either one of two signals can stop the equipment. EMERGENCY STOP One signal for ordinary stops. ‘The other signal is for ________stops only. When you want the boom of the hoist or crane to be moved. ints to pick up a load, give either the “boom up” signal or the “boom down” signal to the 42 shut-off, or remove, or cut power lines one man only communicate, or talk signals directly toward only your right hand and arm emergency position, or place operator358. The “boom up” signal looks like this to the operator. You make a fist of your right hand with the thumb extended upward. You move your hand and arm________ to in cate direction of movement of the boom. 359. The “boom down” signal looks like this to the operator. ‘You make a fist of your right hand so that the thumb extends downward, and move your hand and arm ——-—o indicate direction of movement of the boom, 60. When you are ready to have the load raised or lowered, give either a “hoist load” or a “__ — load’ signal to the operator. 61. Look at the “hoist load” signal. You raise your arm (waist-high/head-high) and de- scribe a (clockwise circular/up-and-down) movement with your right hand to tell the operator to hoist the load. 43 upward downward lower head-high clockwise circular