TABLE OF CONTENTS EQUIPMENT: SOUTH FACE SPRAY CIRCULATION PUMP ( )...4

Transcription

1 TABLE OF CONTENTS EQUIPMENT: NORTH FACE SPRAY CIRCULATION PUMP ( )...3 EQUIPMENT: SOUTH FACE SPRAY CIRCULATION PUMP ( )...4 EQUIPMENT: ONCE THROUGH WATER RETURN PUMP ( 112 )...5 EQUIPMENT: CHUTE COOLING WATER PUMP ( )...6 EQUIPMENT: DRYER SPILLAGE CONVEYOR ( 005 )...7 EQUIPMENT: JEFFERY FEEDER & PRODUCT BIN ( 012 & 143 )...8 EQUIPMENT: AMMONIA COOLER (400)...9 EQUIPMENT: BFL AMMONIA VAPORIZER (403)...11 EQUIPMENT: AIR CHILLER (404)...12 EQUIPMENT: BAGHOUSE FAN ( 1311 )...13 EQUIPMENT: BAGHOUSE SCREW CONVEYOR ( 2111 )...14 EQUIPMENT: DRYER/COOLER EQUIPMENT SCRUBBER (117)...15 EQUIPMENT: DRYER & COOLER CYCLONES ( 380 & 381 )...16 EQUIPMENT: DAP WATER COLLECTION TANK ( 154 )...17 EQUIPMENT: COOLER BAGHOUSE ( 306 )...18 EQUIPMENT: 54% ACID STORAGE TANK (502)...19 EQUIPMENT: 54% ACID STORAGE TANK SPLITTER BOX (650)...21 EQUIPMENT: AIR PRE-HEATER ( 403 )...22 EQUIPMENT: DEFOAMER TANK ( 511 )...23 EQUIPMENT: AMMONIA COOLER (400)...24 EQUIPMENT: BFL AMMONIA VAPORIZER (403)...26 EQUIPMENT: AIR CHILLER (1311)...27 EQUIPMENT: NO.1 54% FEED PUMP (102A)...29 EQUIPMENT: NO.2 54% FEED PUMP (102B)...31 EQUIPMENT: BFL CONDENSATE PUMP...33 EQUIPMENT: TAIL GAS SCRUBBER CIRCULATION PUMP (116/117)...34 EQUIPMENT: "A" R/G PRE-SCRUBBER PUMP (119)...36 EQUIPMENT: "B" R/G PRE-SCRUBBER PUMP (120)...38 EQUIPMENT: "A" ACID SCRUBBER PUMP (120A)...40 EQUIPMENT: "B" ACID SCRUBBER PUMP (120B)...41 EQUIPMENT: DEFOAMER PUMP (233A)...43 EQUIPMENT: "A" SLURRY PUMP (122A)...44 EQUIPMENT: "B" REACTOR SLURRY PUMP (122B)...45 EQUIPMENT: "A" EFFLUENT RETURN PUMP (134A)...46 EQUIPMENT: "B" EFFLUENT RETURN PUMP (134B)...47 EQUIPMENT: CYCLONIC SCRUBBER PUMP(120)...49 EQUIPMENT: ONCE THRU WATER PUMP (154)...50 EQUIPMENT: HYDRAULIC SYSTEM PUMPS (640E-W)...51 EQUIPMENT: INTREMEDIATE CONVEYOR (016)...53 EQUIPMENT: "A" & "B" DEDUSTING SCREEN...55 EQUIPMENT: RECYCLE ELEVATOR (102)...56 EQUIPMENT: GRANULATOR (103)...58 EQUIPMENT: LUMPBREAKER (105)...60 EQUIPMENT: SCREENS FEED ELEVATOR (106)

2 EQUIPMENT: PROCESS SCREENS (107A-D)...63 EQUIPMENT: CAGE MILLS INNER AND OUTER CAGE (108A-D)...64 EQUIPMENT: DRAG FLIGHT CONVEYOR (110)...65 EQUIPMENT: PRODUCT COOLER (111)...67 EQUIPMENT: PRODUCT ELEVATOR (113)...68 EQUIPMENT: PRODUCT CONVEYOR (141)...69 EQUIPMENT: FINES CONVEYOR (146)...70 EQUIPMENT: NORTH DAP DISTRIBUTION CONVEYOR (415)...71 EQUIPMENT: DAP DISTRIBUTION CONVEYOR AND TRIPPER (417/417A)...72 EQUIPMENT: PRE-SCREEN RECYCLE CONVEYOR...74 EQUIPMENT: ROTARY DRYER (104)...75 EQUIPMENT: COMBUSTION CHAMBER (104-1)...76 EQUIPMENT: I.D.FAN (116)...78 EQUIPMENT: DRYER/COOLER EQUIPMENT SCRUBBER (117)...79 EQUIPMENT: T.G.SCRUBBER (148)...81 EQUIPMENT: BURNER BLOWER (153)...83 EQUIPMENT: CYCLONIC SCRUBBER (310)...84 EQUIPMENT: R/G PRE-SCRUBBER...86 EQUIPMENT: BAGHOUSE AIR COMPRESSOR ( )...88 EQUIPMENT: 54% ACID STORAGE TANK AGITATOR (034)...89 EQUIPMENT: REACTOR (501)...90 EQUIPMENT: 54% ACID STORAGE TANK (502)...93 EQUIPMENT: 54% ACID STORAGE TANK SPLITTER BOX (650)

3 PLANT: DAP-1 EQUIPMENT: NORTH FACE SPRAY CIRCULATION PUMP ( ) EQUIPMENT NUMBER: DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Stop the North face spray circulation pump( ) by pressing the stop button on the panel board. 1. Accidental start-up. 2. Open and lock the disconnect for North face spray circulation pump( ) in the Motor Control Center (MCC) with a Production Lock. 2. Electrical/480 volts. 2. Cubical explosion. 3. Close and chain lock the 12" Suction valve and the 8" Discharge valve with a Production Lock. Open and tag the drain valve. 3. Pond water/mildly acidic. 3. Eye/skin irritation 4. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 4. No hazard. 5. After work completion, inspect equipment and 5. None 5. No hazard. 3

4 PLANT: DAP-1 EQUIPMENT: SOUTH FACE SPRAY CIRCULATION PUMP ( ) EQUIPMENT NUMBER: DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Stop the South face spray circulation pump( ) by pressing the stop button on the panel board. 1. Accidental start-up. 2. Open and lock the disconnect for South face spray circulation pump( ) in the Motor Control Center (MCC) with a Production Lock. 2. Electrical/480 volts. 2. Cubical explosion. 3. Close and chain lock the 12" Suction valve and the 8" Discharge valve with a Production Lock. Open and tag the drain valve. 3. Pond water/mildly acidic. 3. Eye/skin irritation 4. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 4. No hazard. 5. After work completion, inspect equipment and 5. None 5. No hazard. 4

5 PLANT: DAP-1 EQUIPMENT: ONCE THROUGH WATER RETURN PUMP ( 112 ) EQUIPMENT NUMBER: 112 DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Stop the Once through water return pump( 112) by pressing the stop button on the panel board. 1. Accidental start-up. 2. Open and lock the disconnect for Once through water return pump( 112) in the Motor Control Center (MCC) with a Production Lock. 2. Electrical/480 volts. 2. Cubical explosion. 3. Close and chain lock the 2" Suction valve and the 2" Discharge valve with a Production Lock. Open and tag the drain valve. 3. Fresh water. 3. No hazard 4. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 4. No hazard. 5. After work completion, inspect equipment and 5. None 5. No hazard. 5

6 PLANT: DAP-1 EQUIPMENT: CHUTE COOLING WATER PUMP ( ) EQUIPMENT NUMBER: DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Stop the Chute Cooling Water pump( ) by pressing the stop button on the panl board. 1. Accidental start-up. 2. Open and lock the disconnect on the Chute Cooling Water pump( ) in the Motor Control Center (MCC) with a Production Lock. 2. Electrical/480 volts. 2. Cubical explosion. 3. Close and chain lock the 2" Suction valve and the 2" Discharge valve with a Production Lock. Open and tag the drain valve. 3. Fresh water. 3. No hazard 4. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 4. No hazard. 5. After work completion, inspect equipment and 5. None 5. No hazard. 6

7 PLANT: DAP-1 EQUIPMENT: DRYER SPILLAGE CONVEYOR ( 005 ) EQUIPMENT NUMBER: 005 DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Stop the Dryer Spillage Conveyor (005) by pushing the stop button on the panel board. 2. Open and lock the disconnects for the Dryer Spillage Conveyor (005) in the DAP 1 Motor Control Center (MCC) with a Production Lock. 2. Electrical/480 volts. 1. Accidental start-up. 2. Cubical explosion. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 3. None 3. No hazard. 4. After work completion, inspect equipment and 4. No hazard. 7

8 PLANT: DAP-1 EQUIPMENT: JEFFERY FEEDER & PRODUCT BIN ( 012 & 143 ) EQUIPMENT NUMBER: 012 & 043 DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Stop the Jeffery feeder by pushing the stop button on the panelboard. 1. Accidental start-up. 2. Open and lock the disconnects for the Jeffery feeder in the DAP 1 Motor Control Center (MCC) with a Production Lock. 3. If entry into the product bin is required the Screens Feed Elevator and the primary screens must also be locked out. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Electrical/480 volts 4.. None 5.. None 2. Cubical explosion. 3. Cubical explosion 4. No hazard. 5. No hazard. 8

9 EQUIPMENT: AMMONIA COOLER (400) EQUIPMENT NUMBER: DWG. NO.: 42-F-0030/42-F-0031 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 ** Prior to begining repairs Steam Purge the entire system. ** 1. Close and chain lock the 3" Ammonia Supply line valve located behind the Granulator, with a Production Lock. Open and tag 1" vent valve. Install a Stainless Steel Blind. 2. Close and chain lock Ammonia Chiller 3" exit valve and the 4" exit valve with a Production Lock. Open and tag 3/4" vent valve. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 4. After work completion, inspect equipment and 1. Ammonia/250 PSIG. 2. Ammonia/250 PSIG. 3. None 1. Health/Fire/Explosion. 2. Health/Fire/Explosion. 3. No hazard. 4. No hazard. 9

10 10

11 EQUIPMENT: BFL AMMONIA VAPORIZER (403) EQUIPMENT NUMBER: DWG. NO.: 42-F-0031/42-F-0031 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Close and chain lock the Main Ammonia Supply line Valve (on the Granulator Floor). Steam Purge the entire system to the Reactor. 2. Close and chain lock 4" Ammonia Supply Line valve. Open and tag the 2" Vent valve. 3. Close and chain lock 6" L.P. Steam valve with a Production Lock. 4. Employees working on this equipment will place their personal lock(s) on the valves designated. 5. After work completion, inspect equipment and reverse the procedure to put the equipment back in 1. Ammonia liquid and vapors/250 PSIG. L.P. Steam 45 PSIG. 2. Ammonia liquid and vapors/250 PSIG. 3. L.P. Steam 45 PSIG. Ammonia vapors. 5. None 1. Health/Fire/Explosion. Thermal burns. 2. Health/Fire/Explosion. 3. Thermal burns/health. 4. No hazard. 5. No hazard. 11

12 EQUIPMENT: AIR CHILLER (404) EQUIPMENT NUMBER: DWG. NO.: 42-F-0050/42-F-0036 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Cooler Vent Fan (116) by pushing the stop button on the panel board. 2. Close and chain lock the 3" Ammonia Supply valve located on the North side of DAP 1, with a Production Lock. Steam Purge the entire system. Open and tag Vent valve. 3. Close and tag 3" inlet valve at the Air Chiller, and 8" outlet valve Open and tag 2" bleed valve and 3/4" bleed valve. 4. Employees working on this equipment will place their personal lock(s) on the valves and disconnect designated. 5. After work completion, inspect equipment and 2. Ammonia/150 PSIG. M. P. Steam 3. Ammonia/150 PSIG. 6. None 7. None 1. Accidental start-up. 2. Health/Thermal burns. Personal injury. 3. Health/Personal injury. 6. No hazard. 7. No hazard. 12

13 PLANT: DAP-1 EQUIPMENT: BAGHOUSE FAN ( 1311 ) EQUIPMENT NUMBER: 1311 DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Stop the Baghouse Fan motor (1311) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Baghouse Fan motor (1311) in the Motor Control Center (MCC) with a production lock. 3. Wait for the I.D.Fan Motor to completely stop rotating (turning). 4. Employees working on this fan will place their personal lock(s) on the equipment designated. 2. Electrical/480 volts. 3. Fan rolling backward. 1. Accidental start-up. 2. Cubical explosion. 3. Personal injury. 4. No hazard. 5. After work completion, inspect equipment and reverse procedures to put equipment back in 5. None 5. No hazard. 13

14 PLANT: DAP-1 EQUIPMENT: BAGHOUSE SCREW CONVEYOR ( 2111 ) EQUIPMENT NUMBER: 2111 DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Stop the Baghouse Screw Conveyor (2111) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Baghouse Screw Conveyor (2111) in the Motor Control Center (MCC) with a Production Lock. 2. Electrical/480 volts. 1. Accidental start-up. 2. Cubical explosion. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 3. None 3. No hazard. 4. After work completion, inspect equipment and 4. No hazard. 14

15 EQUIPMENT: DRYER/COOLER EQUIPMENT SCRUBBER (117) EQUIPMENT NUMBER: 117 DWG. NO.: 42-F-0037 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Acid Scrubber Pumps (120A/120B) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Acid Scrubber Pumps (120A/120B) in the Motor Control Center (MCC). 3. Close and chain lock the 3" Pond Water valve, the 8" Venturi Spray valve, and the 1 1/2" H2S04 valve. Close and chain lock the 1 1/2" Steam valves and the 1" Defoamer valve. Close and chain lock the 4" 30% PPA valve and the 4" AP line valve with Production Locks. Open and tag the 6" C/E Scrubber Drain valve. 2. Electrical/480 volts. 3. Pond water/mildly acidic. 55 PSIG Steam. Phosphoric Acid (54%/30%) 180 o + F. Sulfuric Acid (93%). 1. Accidental start-up. 2. Cubical explosion. 3. Eye/Skin irritation. Chemical/Thermal burns. Personal injury. 15

16 EQUIPMENT: DRYER/EQUIPMENT SCRUBBER EQUIPMENT NUMBER: 117 DWG. NO.: 42-F Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and 5. None 4. No hazard. 5. No hazard. 16

17 PLANT: DAP-1 EQUIPMENT: DRYER & COOLER CYCLONES ( 380 & 381 ) EQUIPMENT NUMBER: 380 & 381 DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER If entry into the Dryer and Cooler cyclones is required the Tailgas Scrubber must be shutdown and locked out. 2. Shut down the Tailgas Scrubber fan (116)from the panelboard and lock it out in the MCC. 1. Excess draft or air flow in the ducts. 2. Electrical / 480 volts. 1. Physical injury 2. Cubical explosion 16

18 PLANT: DAP-1 EQUIPMENT: DAP WATER COLLECTION TANK ( 154 ) EQUIPMENT NUMBER: 154 DWG. NO.: 170B-123 AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Empty or control Tank inventory as needed for repairs. 2. Close and chain lock the 3" O.T.W. Supply line valve. Close and tag the 2" Pump Suction valve, open and tag the Tank 1" Drain valve. 1. None 2. O.T.W. under pressure. 1. No hazard. 2. Personal injury. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 3. None 3. No hazard. 4. After work completion, inspect the equipment and reverse procedures to put the equipment back in 4. No hazard. 17

19 PLANT: DAP-1 EQUIPMENT: COOLER BAGHOUSE ( 306 ) EQUIPMENT NUMBER: 306 DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER If entry into the Baghouse dust bin is required the baghouse screw (1311) and the baghouse compressor ( 1313) must be shutdown and locked out in the MCC. 1. Electrical / 480 volts 1. Cubical explosion 2. Employees working on this equipment will place their personal lock(s) on the equipment designated. 3. After work completion, inspect equipment and 2. No Hazard 3. No hazard 2. No Hazard 3. No hazard 18

20 EQUIPMENT: 54% ACID STORAGE TANK (502) EQUIPMENT NUMBER: DWG. NO.: 42-F-0005 CHAIRMAN: JEF GOLWITZER DATE: 09/26/96 1. Stop the 54% Acid Storage Tank Agitator (034) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the 54% Acid Storage Tank Agitator (034) in the Motor Control Center (MCC) with a Production Lock. 3. Close and chain lock the 4" Merchant Acid valve, the 4" 54% Acid valve, the 4" Sludge line Valve, and the 4" A.P. line Valve with a Production Lock. 4. Blind or chain and lock the 4" Merchant Acid line, the 4" 54% line, the 4" Sludge line, and the All-Purpose (A-P) line at Clarification (Double Block and Bleed. 2. Electrical/120 volts. 3. Phosphoric acid 180 o F. 4. Phosphoric acid 180 o F. 1. Unexpected power surge/release of stored energy. Accidental start-up. 2. Cubical explosion. 3. Chemical/thermal burns. 4. Chemical/thermal burns. 19

21 EQUIPMENT: 54% ACID STORAGE TANK EQUIPMENT NUMBER: DWG. NO.: 42-F Employees working on this equipment will place their personal lock(s) on the disconnect. 6. After work completion, inspect equipment and 5. None 6. None 5. No hazard. 6. No hazard. 20

22 EQUIPMENT: 54% ACID STORAGE TANK SPLITTER BOX (650) EQUIPMENT NUMBER: DWG. NO.: 42-F-0005 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Chain and Lock the 4" Merchant Acid, the 4" 54% Acid, the 4" Sludge, the 4" All Purpose (A- P) line Feed lines at the 54% Acid Storage Tank Splitter Box. The above Supply line valves will be chained and locked at their source (DAP and Clarification). 2. Employees working on this equipment will place their personal lock(s) on the valves designated. 3. After work completion, inspect equipment and 1. Phosphoric acid 180 o F. 2. None 3. None 1. Chemical/thermal burns. 2. No hazard. 3. No hazard. 21

23 PLANT: DAP-1 EQUIPMENT: AIR PRE-HEATER ( 403 ) EQUIPMENT NUMBER: 403 DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER If entry is required into the pre-heater the burner blower (153 )and the main 150 lb. steam supply valve to the pre-heater must be locked out lb steam and excess draft or air pressure. 1. Physical injury from steam and air flow 2. Open and lock the disconnect for the burner blower (153 ) in the Motor Control Center (MCC) with a Production Lock. 3. Close and chain lock the main 150 lb. steam valve to the pre-heater. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and 2. Electrical / 480 volts lb. steam. 4. No Hazard 5. No Hazard 2. Cubical explosion 3. Thermal burns 4. No hazard 5. No hazard 22

24 SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: DEFOAMER TANK ( 511 ) EQUIPMENT NUMBER: 511 DWG. NO.: AREA SAFETY COMMITTEE YES CHAIRMAN: JEFF A. GOLWITZER DATE: OCTOBER Empty Reagent Tank (511) or control inventory as required for repairs. 2. Close a chain lock the Utility Water supply line vlve, and the 3" Reagent Supply line valve with a Production Lock. Open and tag the 2" Tank Drain valve. Close and tag the Discharge valves on the three (2) Defoamer Transfer Pumps. 1. Defoamer Reagent. 2. Steam, 150 PSIG/Defoamer Reagent/Water. 1. Eye irritation/slippery liquid. 2. Eye irritation/thermal burns/slippery conditions. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 3. None 3. No hazard. 4. After work completion, inspect the equipment and reverse procedures to put the equipment back in 4. No hazard. 23

25 PAGE 24 EQUIPMENT: AMMONIA COOLER (400) EQUIPMENT NUMBER: DWG. NO.: 42-F-0030/42-F-0031 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 ** Prior to begining repairs Steam Purge the entire system. ** 1. Close and chain lock the 3" Ammonia Supply line valve located behind the Granulator, with a Production Lock. Open and tag 1" vent valve. Install a Stainless Steel Blind. 2. Close and chain lock Ammonia Chiller 3" exit valve and the 4" exit valve with a Production Lock. Open and tag 3/4" vent valve. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 4. After work completion, inspect equipment and 1. Ammonia/250 PSIG. 2. Ammonia/250 PSIG. 3. None 1. Health/Fire/Explosion. 2. Health/Fire/Explosion. 3. No hazard. 4. No hazard. 24

26 07/31/95 * 09/26/96 * 09/26/96 25

27 EQUIPMENT: BFL AMMONIA VAPORIZER (403) EQUIPMENT NUMBER: DWG. NO.: 42-F-0031/42-F-0031 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Close and chain lock the Main Ammonia Supply line Valve (on the Granulator Floor). Steam Purge the entire system to the Reactor. 2. Close and chain lock 4" Ammonia Supply Line valve. Open and tag the 2" Vent valve. 3. Close and chain lock 6" L.P. Steam valve with a Production Lock. 4. Employees working on this equipment will place their personal lock(s) on the valves designated. 5. After work completion, inspect equipment and reverse the procedure to put the equipment back in 1. Ammonia liquid and vapors/250 PSIG. L.P. Steam 45 PSIG. 2. Ammonia liquid and vapors/250 PSIG. 3. L.P. Steam 45 PSIG. Ammonia vapors. 5. None 1. Health/Fire/Explosion. Thermal burns. 2. Health/Fire/Explosion. 3. Thermal burns/health. 4. No hazard. 5. No hazard. 07/28/95 * 02/26/96 * 09/26/96 26

28 EQUIPMENT: AIR CHILLER (1311) EQUIPMENT NUMBER: DWG. NO.: 42-F-0050/42-F-0036 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Cooler Vent Fan (116) by pushing the stop button on the panel board. 2. Close and chain lock the 3" Ammonia Supply valve located on the North side of DAP 1, with a Production Lock. Steam Purge the entire system. Open and tag Vent valve. 3. Close and tag 3" inlet valve at the Air Chiller, and 8" outlet valve Open and tag 2" bleed valve and 3/4" bleed valve. 4. Employees working on this equipment will place their personal lock(s) on the valves and disconnect designated. 5. After work completion, inspect equipment and 2. Ammonia/150 PSIG. M. P. Steam 3. Ammonia/150 PSIG. 6. None 7. None 1. Accidental start-up. 2. Health/Thermal burns. Personal injury. 3. Health/Personal injury. 6. No hazard. 7. No hazard. 27

29 07/31/95 * 02/26/96 * 08/19/96 * 09/26/96 28

30 SPECIFIC LOCKOUT PROCEDURE PAGE 29 EQUIPMENT: No.1 54% FEED PUMP (102A) EQUIPMENT NUMBER: A CHAIRMAN: JEFF GOLWITZER DWG. NO.: 42-F-0005 DATE: 09/26/96 1. Stop the No.1 54% Feed Pump (102A) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the No.1 54% Feed Pump (102A) in the Motor Control Center (MCC) with a Production Lock. 3. Close and chain lock the 6" Suction valve and the 4" Discharge valve with a Production Lock. Open and tag the 3/4" drain valve. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Phosphoric acid 180 o F. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Chemical/thermal burns. 4. No hazard. 5. No hazard. 29

31 06/21/95 * 09/26/96 * 09/26/96 30

32 EQUIPMENT: No.2 54% FEED PUMP (102B) EQUIPMENT NUMBER: B DWG. NO.: 42-F-0005 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the No.2 54% Feed Pump (102B) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the No.2 54% Feed Pump (102B) in the Motor Control Center (MCC) with a Production Lock. 3. Close and chain lock the 6" Suction valve and the 4" Discharge valve with a Production Lock. Open and tag the 3/4" drain valve. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Phosphoric acid 180 o F. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Chemical/thermal burns. 4. No hazard. 5. No hazard. 31

33 06/21/95 * 09/26/96 * 09/26/96 32

34 EQUIPMENT: BFL CONDENSATE PUMP EQUIPMENT NUMBER: DWG. NO.: 42-F-0031 CHAIRMAN: JEFF GOLWITZER DATE: 10/17/96 1. Stop the BFL Condenstae Transfer Pump by pushing the stop button on the panel board. 2. Open and lock the disconnect for the BFL Condensate Transfer Pump in the Motor Control Center (MCC) with a production lock. 3. Close and chain lock the 2" Suction valve and the 2" discharge valve with a Production Lock. Open and tag the 1" drain valve. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and reverse procedures to put equipment back in 2. Electrical/480 volts. 3. Ammoniated liquid. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Personal injury/ammonia inhalation 4. No hazard. 5. No hazard. 07/24/95 * 10/11/96 * 10/17/96 33

35 EQUIPMENT: TAIL GAS SCRUBBER CIRCULATION PUMP (116/117) EQUIPMENT NUMBER: 116/117 DWG. NO.: 42-F-0038 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Tail Gas Scrubber circulation pump (116/117) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Tail Gas Scrubber circulation Pump (116/117) in the Motor Control Center (MCC) with a Production Lock. 3. Close and chain lock the 10" Suction valve(s) and the 8" Discharge valve(s) for North and/or South Pump as required, with a Production Lock. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Pond water/mildly acidic. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Eye/skin irritation. 4. No hazard. 5. No hazard. 34

36 07/20/95 * 09/26/96 * 09/26/96 35

37 EQUIPMENT: "A" R/G PRE-SCRUBBER PUMP (119) EQUIPMENT NUMBER: 119 DWG. NO.: 42-F-0031 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop "A" R/G Pre-scrubber Pump (119) by pushing the stop button on the panel board. 2. Open and lock the disconnect for "A" Prescrubber Pump (119) in the Motor Control Center (MCC) with a production lock. 3. Secure the Hydraulic Fluid Supply to the 10" Suction valve and the 10" Discharge valve by the following means: Disable/Disconnect/Drain and/or Lock with a Production Lock. Open and tag the 2" drain valve. 4. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 2. Electrical/480 volts. 3. Phosphoric acid/180 F. 1. Accidental start-up. 2. Cubical explosion. 3. Thermal and chemical burns. 4. No hazard. 36

38 EQUIPMENT: "A" R/G PRE-SCRUBBER PUMP EQUIPMENT NUMBER: 119 DWG. NO.: 42-F After work completion, inspect equipment and 5. None 5. No hazard. 06/09/95 * 02/26/96 * 08/19/96 * 09/26/96 37

39 EQUIPMENT: "B" R/G PRE-SCRUBBER PUMP (120) EQUIPMENT NUMBER: 120 DWG. NO.: 42-F-0031 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop "B" R/G Pre-scrubber Pump (120) by pushing the stop button on the panel board. 2. Open and lock the disconnect for "B" R/G Prescrubber Pump (120) in the Motor Control Center (MCC) with a Production Lock. 3. Secure the Hydraulic Fluid Supply to the 10" Suction valve and the 10" Discharge valve by the following means: Disable/Disconnect/Drain and/or Lock with a Production Lock. Open and tag the 2" drain valve. 4. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 2. Electrical/480 volts. 3. Phosphoric acid/180 F. 1. Accidental start-up. 2. Cubical explosion. 3. Thermal and chemical burns. 4. No hazard. 38

40 EQUIPMENT: "B" R/G PRE-SCRUBBER PUMP EQUIPMENT NUMBER: 120 DWG. NO.: 42-F After work completion, inspect equipment and 5. None 5. No hazard. 06/09/95 * 02/26/96 * 08/19/96 * 09/26/96 39

41 EQUIPMENT: "A" ACID SCRUBBER PUMP (120A) EQUIPMENT NUMBER: 120A DWG. NO.: 42-F-0037 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop "A" Acid Scrubber Pump (120A) by pushing the stop button on the panel board. 2. Open and lock the disconnect for "A" Acid Scrubber Pump in the Motor Control Center (MCC) with a production lock. 3. Valve out Hydraulic Service for the 10" Suction valve and 10" Discharge. Open and tag the 1" drain valve. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and reverse the procedures to put the equipment back into 2. Electrical/480 volts. 3. Phosphoric acid/180 F. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Thermal and chemical burns. 4. No hazard. 5. No hazard. 07/20/95 * 08/19/96 * 09/26/96 40

42 EQUIPMENT: "B" ACID SCRUBBER PUMP (120B) EQUIPMENT NUMBER: 120B DWG. NO.: 42-F-0037 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop "B" Acid Scrubber Pump (120B) by pushing the stop button on the panel board. 2. Open and lock the disconnect for "B" Acid Scrubber Pump (120B) in the Motor Control Center (MCC) with a production lock. 3. Valve out Hydraulic Service to the 10" Suction valve and the 10" Discharge valve with a Production Lock. Open and tag the 1" drain valve. 4. Employees working on this equipment will place their personal(s) on the equipment designated. 5. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Phosphoric acid/180 F. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Thermal and chemical burns. 4. No hazard. 5. No hazard. 41

43 07/20/95 * 08/19/96 * 09/26/96 42

44 EQUIPMENT: DEFOAMER PUMP (233A) EQUIPMENT NUMBER: A DWG. NO.: 44-F-0037 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Defoamer Metering Pump (233A) by pushing the stop button in the field. 2. Disconnect the Defoamer Metering Pump (233A) by tagging receptacle located in the DAP 1 Control Room. 3. Close and chain lock the Suction valve with a Production Lock. Close and tag 1" Discharge valve. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and reverse the procedures to put the equipment back in 2. Electrical/120 volts. 3. Defoamer (oil) under pressure. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Personal injury. 4. No hazard. 5. No hazard. 07/20/95 * 08/19/96 * 09/26/96 43

45 EQUIPMENT: "A" SLURRY PUMP (122A) EQUIPMENT NUMBER: 122A DWG. NO.: 42-F-0030 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1.Stop "A" Slurry Pump (122A) by pushing the stop button on the panel board. 2.Open and lock the disconnect for "A" Slurry Pump (122A) in the Motor Control Center (MCC) with a Production Lock. 3.Close and chain lock the 6" suction valve and the 4" discharge valve with a Production Lock. Open and tag the 1" drain valve. Close and tag the 3" Pond Water valve. 4.Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 5.After work completion, inspect equipment and 1.Electrical/120 volts. 2.Electrical/480 volts. 3.Ammoniated slurry/235 o F. Pond water/mildly acidic. 4.None 5.None /08/95 * 02/26/96 * 08/19/96 * 09/26/96 44

46 EQUIPMENT: "B" REACTOR SLURRY PUMP (122B) EQUIPMENT NUMBER: 122B DWG. NO.: 44-F-0030 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the "B" Reactor Slurry pump (122B) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Reactor Slurry pump (122B) in the Motor Control Center (MCC) with a production lock. 3. Close and chain lock the 6" Suction valve and 4" Discharge valve with a Production Lock. Open and tag the 1" Drain valve. Close and tag the 3" Pond Water valve. 4. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 5. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Ammoniated slurry/235 F. Pond water/mildly acidic. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Chemical/thermal burns. 5. No hazard. 06/08/95 * 02/26/96 * 08/19/96 * 09/26/96 45

47 EQUIPMENT: "A" EFFLUENT RETURN PUMP (134A) EQUIPMENT NUMBER: 134A DWG. NO.: 42-F-0038 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop "A" Effluent Return Pump (134A) by pushing the stop button on the panel board. 2. Open and lock the disconnect for "A" Effluent Return Pump (134A) in the Motor Control Center (MCC) with a Production Lock. 3. Close and chain lock the 12" Suction valve and the 8" Discharge valve with a Production Lock. Open and tag the drain valve. 4. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 5. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Pond water/mildly acidic. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Eye/skin irritation 4. No hazard. 5. No hazard. 06/12/95 * 02/26/96 * 08/19/96 * 09/26/96 46

48 EQUIPMENT: "B" EFFLUENT RETURN PUMP (134B) EQUIPMENT NUMBER: 134B DWG. NO.: 42-F-0038 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop "B" Effluent Return Pump (134B) by pushing the stop button on the panel board. 2. Open and lock the disconnect for "B" Effluent Return Pump (134B) in the Motor Control Center (MCC) with a Production Lock. 3. Close and chain lock the 12" Suction valve and the 8" Discharge valve with a Production Lock. Open and tag the drain valve. 4. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 6. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Pond water/mildly acidic. 5. None 1. Unexpected power surge/release of stored energy. Accidental start-up. 2. Cubical explosion. 3. Eye/skin irritation. 4. No hazard. 5. No hazard. 47

49 06/12/95 * 02/26/96 * 08/19/96 * 09/26/96 48

50 EQUIPMENT: CYCLONIC SCRUBBER PUMP(120) EQUIPMENT NUMBER: DWG. NO.: 42-F-0038 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Cyclonic Scrubber Pump (120) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Cyclonic Scrubber Pump (120) in the Motor Control Center (MCC) with a Production Lock. 3. Close and chain lock the 6" Suction valve and the 4" Discharge valve with a Production Lock. Open and tag the 3" Drain valve. 4. Employees working on this equipment will place their personal lock(s) in the disconnect and valves designated. 5. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Process Water. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. No hazard. 4. No hazard. 5. No hazard. 07/26/95 * 02/26/96 * 08/19/96 * 09/26/96 49

51 EQUIPMENT: ONCE THRU WATER PUMP (154) EQUIPMENT NUMBER: 154 DWG. NO.: 170B-123 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/97 1. Stop the DAP Water Collection Tank Pump (154) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the DAP Water Collection Tank Pump (154) in the DAP 1 Motor Control Center (MCC) with a Production Lock. 3. Close and chain lock the 2" Pump Suction valve, the 2" Pump Discharge valve, and the 2" Crossover valve from the Chute Cooling Pump with a Production Lock. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect the equipment and 12/06/95 * 09/26/96 * 09/26/96 2. Electrical/480 volts. 3. Once thru water. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Personal injury. 4. No hazard. 5. No hazard 50

52 EQUIPMENT: HYDRAULIC SYSTEM PUMPS (640E-W) EQUIPMENT NUMBER: E-W DWG. NO.: CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Hydraulic System Pumps (640E-W) by pushing the stop button on the panel board. 2. Open and lock the disconnects for the Hydraulic System Pumps (640E-W) in the Motor Control Center (MCC) with a Production Lock. 3. Close and tag the Discharge valve on the Accumulator and bleed the Hydraulic System down by opening and closing the cylinder on the equipment to be repaired. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 2. Electrical/480 volts. 3. Hydraulic Fluid 750 PSIG. 1. Accidental start-up. 2. Cubical explosion. 3. Personal injury/health. 51

53 EQUIPMENT: HYDRAULIC SYSTEM PUMPS EQUIPMENT NUMBER: E-W DWG. NO.: 5. After work completion, inspect equipment and 5. None 5. No hazard. 07/26/95 * 09/26/96 * 09/26/96 52

54 PAGE 53 EQUIPMENT: INTREMEDIATE CONVEYOR (016) EQUIPMENT NUMBER: DWG. NO.: 50-F-0002 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop or divert the Material flow away form the Intermediate Conveyor (016). 2. Stop the Intermediate Conveyor (016) by pushing the stop button on the panel board. 3. Open and lock the disconnect for the Intermediate Conveyor (016) in the DAP 1 Motor Control Center (MCC) with a Production Lock. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and 1. Granulated material flow. 2. Electrical/120 volts. 3. Electrical/480 volts. 5. None 1. Personal injury. 2. Accidental start-up. 3. Cubical explosion. 4. No hazard. 5. No hazard. 53

55 06/14/96 * 09/26/96 * 09/26/96 54

56 EQUIPMENT: "A" & "B" DEDUSTING SCREEN EQUIPMENT NUMBER: DWG. NO.: CHAIRMAN: JEFF GOLSITZER DATE: 09/26/96 1. Stop the "A" or "B" Dedusting Screen by pushing the stop button on the Field switch. 2. Open and lock the disconnect for the "A" or "B" Dedusting Screen in the Motor Control Center (MCC) with a Production Lock. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 4. After work completion, inspect equipment and 2. Electrical/480 volts. 3. None 1. Accidental start-up. 2. Cubical explosion No hazard. 07/26/95 * 01/29/96 * 08/19/96 55

57 EQUIPMENT: RECYCLE ELEVATOR (102) EQUIPMENT NUMBER: 102 DWG. NO.: 42-F-0035 AREA SAFETY COMMITTEE CHAIRMAN: DATE: 1. Stop the Recycle Elevator (102) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Recycle Elevator (102) in the Motor Control Center (MCC) with a Production Lock. If entry is required Steps 3 and 4 apply. 3. Stop the Dragflight (110) by pushing the stop button on the panel board. 4. Open and lock the disconnect for the Dragflight (110) the Motor Control Center (MCC) with a Production Lock. 2. Electrical/480 volts. 3. Electrical/120 volts. 4. Electrical/480 volts. 1. Accidental start-up. 2. Cubical explosion. 3. Accidental start-up. 4. Cubical explosion. 56

58 EQUIPMENT: RECYCLE ELEVATOR (102) EQUIPMENT NUMBER: 102 DWG. NO.: 42-F Employees working on this equipment will place their personal lock(s) on the equipment designated. 6. After work completion, inspect equipment and 5. None 6. None 5. No hazard. 6. No hazard. 07/20/95 * 09/26/96 * 09/26/96 57

59 EQUIPMENT: GRANULATOR (103) EQUIPMENT NUMBER: DWG. NO.: 42-F-0034/30/31/35 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the granulator (103) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Granulator (103) in the Motor Control Center (MCC) with a Production Lock. If entry is necessary, steps 3 through 7 apply. 3. Stop the Recycle Elevator (102) and "A" and "B" Slurry Pumps (122A-B) by pushing the stop button on the panel board. 4. Open and lock the disconnects for the Recycle Elevator (102) and "A" & "B" Slurry Pumps (122A-B) in the Motor Control Center (MCC) with a Production Lock. 5. Close and chain lock (DOUBLE BLOCK & BLEED) the NH3 Supply Line valves to the Sparger with a Production lock. Steam Purge the NH3 Sparger to the Granulator (103). 2. Electrical/480 volts. 3. Electrical/120 volts. 4. Electrical/480 volts. 5. Ammonia liquid and vapors. Medium Pressure Steam 150 PSIG. 1. Accidental start-up. 2. Cubical explosion. 3. Accidental start-up. 4. Cubical explosion. 5. Health-Thermal burns. 58

60 EQUIPMENT: GRANULATOR (103) EQUIPMENT NUMBER: DWG. NO.: 42-F-0034/30/31/35 6. Shut compressor breaker off & lock. Close discharge valve to air bladder & open bleed. Check gauges for zero pressure. 7. Close and tag 3" valve and open and tag 3/4" vent valve. Close and chain lock 1" Medium Pressure Steam valve with a Production Lock. 8. Close and chain lock 6" valves on line from BFL Vaporizer and the 2" valve from Ammonia Cooler with a Production Lock. Open and tag 1" Vent valve. 9. Employees working on this equipment will place their personal lock(s) on the disconnect and valves designated. 10. After work completion, inspect equipment and 6. None 7. Ammonia liquid and vapors./steam 150 PSIG 8. Ammonia liquid and vapors./250 PSIG 9. None 10. None 6. No hazard 7. Health/Fire/explosion. 7. Health/Fire/explosion. 8. No hazard. 9. No hazard. Rev. 11/2004 NOTE: Tailgas scrubber fan should be running if acid scrubbers have acid or scrub water in them. 59

61 EQUIPMENT: LUMPBREAKER (105) EQUIPMENT NUMBER: 105 DWG. NO.: 42-F-0032 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Rotary Dryer (104) and the Lump Breaker (105) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Lumpbreaker (105) in the Motor Control Center (MCC) with a Production Lock. ** If Lumpbreaker entry is required, the Rotary Dryer Must Be locked out in the MCC. ** 3. Employees working on this equipment will place their personal lock(s) on the disconnect designated. 4. After work completion, inspect equipment and 2. Electrical/480 volts. 3. None 1. Accidental start-up. 2. Cubical explosion. 3. No hazard. 4. No hazard. 06/22/95 * 02/26/96 * 08/19/96 * 09/26/96 60

62 EQUIPMENT: SCREENS FEED ELEVATOR (106) EQUIPMENT NUMBER: 106 DWG. NO.: 42-F-0032 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Screens Feed Elevator (106) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Screens Feed Elevator (106) in the Motor Control Center (MCC) with a Production Lock. ** If entry to the elevator boot is required, Steps 3 and 4 apply. ** 3. Stop the Rotary Dryer (104) and the Lumpbreaker (105) by pushing the stop buttons on the panel board. 4. Open and lock the disconnects for the Rotary Dryer (104) and Lump Breaker (105) in the Motor Control Center (MCC) with a Production Lock. 2. Electrical/480 volts. 3. Electrical/120 volts. 4. Electrical/480 volts. 1. Accidental start-up. 2. Cubical explosion. 3. Accidental start-up. 4. Cubical explosion. 61

63 EQUIPMENT: SCREENS FEED ELEVATOR EQUIPMENT NUMBER: (106) DWG. NO.: 42-F Employees working on this equipment will place their personal lock(s) on the equipment designated. 6. After work completion, inspect equipment and reverse procedures to put the equipment back into 5. None 6. None 5. No hazard. 6. No hazard. 07/20/95 * 09/26/96 * 09/26/96 62

64 EQUIPMENT: PROCESS SCREENS (107A-D) EQUIPMENT NUMBER: 107A-D DWG. NO.: 42-F-0035 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Divert Material Flow as required. close valve on Hydraulics Cylinder. 2. Stop the Process Screens (107A-D) as required, by pushing the stop button on the panel board or the Field Switch as required. 3. Open and lock the disconnect for the Process Screens (107A-D) as required in the Motor Control Center (MCC) with a Production Lock. 4. Employees working on this equipment will place their personal lock(s) on the disconnect designated. 5. After work completion, inspect equipment and 1. Granulated Material Flow. 2. Electrical/120 volts. 3. Electrical/480 volts. 5. None 1. Personal injury. 2. Accidental start-up. 3. Cubical explosion. 4. No hazard. 5. No hazard. 06/22/95 * 02/26/97 * 08/19/96 * 09/26/96 63

65 EQUIPMENT: CAGE MILLS INNER AND OUTER CAGE (108A-D) EQUIPMENT NUMBER: A-D DWG. NO.: 42-F-0035 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Inner and Outer Cage Mill(s) (108 A- D) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Inner and Outer Cage Mill(s) (108A-D) as needed in the Motor Control Center (MCC) with a Production Lock. 3. Employees working on this equipment will place their personal lock(s) lock on the disconnect designated. 4. After work completion, inspect equipment and 2. Electrical/480 volts. 3. None 1. Unexpected power surge/release of energy. Accidental start-up. 2. Same as above. 3. No hazard. 4. No hazard. 06/22/95 * 02/26/96 * 08/19/96 * 09/26/96 64

66 EQUIPMENT: DRAG FLIGHT CONVEYOR (110) EQUIPMENT NUMBER: DWG. NO.: 42-F-0035 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Drag Flight Conveyor (110) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Drag Flight Conveyor (110) in the Motor Control Center (MCC) with a Production Lock. ** If entry is required steps 3 and 4 will apply. ** 3. Stop the Cage Mills (108 A-D), the Pre-screen Recycle Belt, and the Screens Feed Elevator (106) by pushing the stop button(s) on the panel board. 4. Open and lock the disconnect for the Cage Mills (108 A-D), the Pre-screen Recycle Belt, and the Screens Feed Elevator (106) in the DAP 1 Motor Control Center (MCC) with a Production Lock. 2. Electrical/480 volts. 3. Electrical/120 volts. 4. Electrical/480 volts. 1. Accidental Start-up. 2. Cubical explosion. 3. Accidental Start-up. 4. Cubical explosion. 65

67 EQUIPMENT: DRAG FLIGHT CONVEYOR EQUIPMENT NUMBER: DWG. NO.: 42-F Employees working on this equipment will place their personal lock(s) on the equipment designated. 6. After work completion,inspect equipment and reverse procedures to put the equipment back in 5. None 6. None 5. No hazard. 6. No hazard 06/26/95 * 02/26/96 * 09/26/96 66

68 EQUIPMENT: PRODUCT COOLER (111) EQUIPMENT NUMBER: 111 DWG. NO.: 42-F-0036 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Product Cooler (111) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Product Cooler (111) in the Motor Control Center (MCC) with a Production Lock. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 4. After work completion, inspect equipment and 07/18/95 * 01/29/96 * 08/19/96 * 09/26/96 2. Electrical/480 volts. 3. None 1. Accidental start-up. 2. Cubical explosion. 3. No hazard. 4. No hazard. 67

69 EQUIPMENT: PRODUCT ELEVATOR (113) EQUIPMENT NUMBER: 113 DWG. NO.: 42-F-0036 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Product Cooler (111) and the Product Elevator (113) by pushing the stop button on the panel board. 2. Open and lock the disconnects for the Product Cooler (111) and the Product Elevator (113) in the Motor Control Center (MCC) with a Production Lock. 3. Employees working on this equipment will place their personal lock(s) on the disconnect. 4. After work completion, inspect equipment and reverse procedure to put the equipment back in 2. Electrical/480 volts. 3. None 1. Accidental start-up. 2. Cubical explosion. 3. No hazard. 4. No hazard 07/26/95 * 01/29/96 * 08/19/96 * 09/26/96 68

70 EQUIPMENT: PRODUCT CONVEYOR (141) EQUIPMENT NUMBER: 141 DWG. NO.: 42-F-0036 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Product Conveyor (141) by pushing the stop button on the panel board. 2. Open and lock the disconnects for the Product Conveyor (141) in the DAP 1 Motor Control Center (MCC) with a Production Lock. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 4. After work completion, inspect equipment and 2. Electrical/480 volts. 3. None 1. Accidental start-up. 2. Cubical explosion. 3. No hazard. 4. No hazard. 07/26/95 * 01/29/96 * 08/19/96 * 09/26/96 69

71 EQUIPMENT: FINES CONVEYOR (146) EQUIPMENT NUMBER: 146 DWG. NO.: 170D-140 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Fines Conveyor (146) by pushing the stop button on the panel board in the DAP 1 Control Room. 2. Open and lock the disconnect for the Fines Conveyor (146) in the DAP 1 Motor Control Center (MCC) with a Production Lock. Activate RED FLASHING LIGHT. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 4. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Active equipment traffic area. 1. Unexpected power surge/release of stored energy. Accidental start-up. 2. Cubical explosion. 3. Payloaders. 4. No hazard. 12/05/95 * 01/29/96 * 09/26/96 70

72 EQUIPMENT: NORTH DAP DISTRIBUTION CONVEYOR (415) EQUIPMENT NUMBER: 415 DWG. NO.: 170D-40 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the North DAP Distribution Conveyor (415) by pushing the stop button(s) on the Field switch. 2. Open and lock the North DAP Distribution Conveyor (415) in the DAP 1 Motor Control Center (MCC) with a Production Lock. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 4. After work completion, inspect equipment and 2. Electrical/480 volts. 3. None 1. Accidental start-up. 2. Cubical explosion. 3. No hazard. 4. No hazard. 12/04/95 * 01/29/96 * 08/19/96 * 09/26/96 71

73 EQUIPMENT: DAP DISTRIBUTION CONVEYOR AND TRIPPER (417/417A) EQUIPMENT NUMBER: /417A DWG. NO.: 50-F-0002 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop or divert Material flow away form the DAP Distribution Conveyor and Tripper (417/417A). 2. Stop the DAP Distribution Conveyor and Tripper (417/417A) by pushing the stop button on the panel board. 3. Open and lock the disconnect for the DAP Distribution Conveyor and Tripper (417/417A) in the DAP 1 Motor Control Center (MCC) with a Production Lock. 4. Employees working on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and 1. Granulated material flow. 2. Electrical/120 volts. 3. Electrical/480 volts. 5. None 1. Personal injury. 2. Accidental start-up. 3. Cubical explosion. 4. No hazard. 5. No hazard. 72

74 06/14/96 * 09/26/96 * 09/26/96 73

75 EQUIPMENT: PRE-SCREEN RECYCLE CONVEYOR EQUIPMENT NUMBER: DWG. NO.: 170D-140 CHAIRMAN: JEFF GOLWITZER DATE: 09/26/96 1. Stop the Pre-screen Recycle Conveyor by pushing the stop button on the panel board in the DAP 1 Control Room. 2. Open and lock the disconnect for the Pre-Screen Recycle Conveyor in the DAP 1 Motor Control Center (MCC) with a Production Lock. 3. Employees working on this equipment will place their personal lock(s) on the equipment designated. 4. After work completion, inspect equipment and 2. Electrical/480 volts. 3. None 1. Accidental start-up. 2. Cubical explosion. 3. No hazard. 4. No hazard. 12/05/95 * 09/26/96 * 09/26/96 74

76 EQUIPMENT: ROTARY DRYER (104) EQUIPMENT NUMBER: 104 DWG. NO.: 42-F-0032 CHAIRMAN: JEFF GOLWITZER DATE: 10/17/96 1. Stop the Dryer (104) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Dryer (104) in the Motor Control Center (MCC) with a Production Lock. ** If entry is necessary, Step 3 will apply. 3. Stop the Granulator (103) and the Lumpbreaker (105) by pushing the stop buttons on the panel board. Depending on the work to be performed it may be necessary to stop the Dryer ID Fan (116) and the Burner Blower (153). 4. Employees required to work on this equipment will place their personal lock(s) on the equipment designated. 5. After work completion, inspect equipment and 2. Electrical/480 volts. 3. Electrical/120 volts. 5. None 1. Accidental start-up. 2. Cubical explosion. 3. Accidental start-up. 4. No hazard. 5. No hazard. 07/20/95 * 09/26/96 * 10/17/96 75

77 EQUIPMENT: COMBUSTION CHAMBER (104-1) EQUIPMENT NUMBER: DWG. NO.: 42-F-0032 AREA SAFETY COMMITTEE CHAIRMAN: DATE: 1. Stop the Dryer (104) by pushing the stop button on the panel board. 2. Open and lock the disconnect for the Dryer (104) in the Motor Control Center (MCC) with a Production Lock. ** If entry is necessary, Steps 3 through 5 apply. ** 3. Close, chain lock, and/or open and bleed down Fuel Source valves as required: The 2" Natural Gas valve (or verify that the line is blanked) and the 1" Fuel Oil valve, (or verify that the line is blanked), with a Production Lock. 4. Close and chain lock the 1" valve on the 150 PSIG Atomizing Steam line to the Combustion Chamber with a Production Lock. 2. Electrical/480 volts. 3. Natural Gas/No.6 Fuel Oil/140 o + F. Insufficient oxygen supply. 4. Steam/150 PSIG. Plant air 30 PSIG. 1. Accidental start-up. 2. Cubical explosion. 3. Thermal Burns/Fire or explosion. Health. 4. Thermal burns/personal injury. 76