1 CLEAN BELT TABLES Apr CLEAN UNDER MOVING CONVEYOR Apr CLEAN PRODUCT CHUTES Apr CLEAN TRUCK PITS Apr-08

Transcription

1 TABLE OF CONTENTS FOR # 1 PAGE # SHIPPING UNIT # 1 REVISED 1 CLEAN BELT TABLES Apr-08 2 CLEAN UNDER MOVING CONVEYOR Apr-08 3 CLEAN PRODUCT CHUTES Apr-08 4 CLEAN TRUCK PITS Apr-08 5 CLEAN CONVEYOR MAGNETS Apr-08 6 FILL OIL TANK ON RECLAIMER Apr-08 7 CLEAN LUMP BREAKER Apr-08 8 MOVE RECLAIMER TO MAINTENANCE AREA Apr-08 9 CHANGING PRODUCTS AND WAREHOUSES Apr CLEAN RAIL BIN Apr CLEAN TRUCK BIN Apr CLEAN RIBBON BLENDER Apr CLEAN HIGH SPEED ELEVATOR BOOT. Apr CLEAN RIBBON BLENDER ELEVATOR BOOT. Apr CLEAN BLENDER GRID Apr STARTING RECLAIM HOPPERS. Apr RECLAIMER - DRESSING PILE Apr DRAINING OIL BARRICADE Apr CLEANING OIL BARRICADE Apr VALVING IN COATING OIL SYSTEM Apr CLEAN INSIDE RAIL SCALE Apr CLEAN TRUCK AND RAIL DIVERTER Apr RAILCAR LOADING Apr TRUCK LOADING # 1 Apr PLANT INSPECTION Apr INSPECTION OF G - 3 & W.H. # 1 Apr-08

2 JOB SAFETY HAZARD ANALYSIS PAGE 1 WRITTEN BY: MIKE WESSON TOPIC: CLEANING BELT TABLES APPROVED BY: ED POLLARD 1. Secure belt drive switchgear in the MCC room by 1. Conveyor still running, and cubical explosion. 1 Stand to side of cubical with proper ppe on while throwing placing the switchgear in the off position and applying switch gear out. ( Hard hat and safety glasses. a blue production lock.( See lock out procedures.) 2. Field test start / stop switch in the field and on panel 2. Serious injury could occur if belt is accidentally started up. 2. Verify lock out and field test. board to verify lockout. 3. Attach "RED" barricade tape with tags around belt table 3. Possible injury to people around and/or under belt table area. 3. By applying the" RED" barricade tape with tags, this will keep area from belt area all the way down to the bottom floor. anyone from entering the affected work area 4. If using an air lance to remove material from belt table 4. Injury and property damage could occur if the three foot clearance is not 4. Supervisor will verify that the 3 foot distance can be maintained a lock out may not be required as long as you maintain a maintained. and if not, then the belt will be locked out for cleaning. 3' ( 3 foot) distanced from belt and table. This 3 foot area is from the end of the air lance to the belt/table. 5. Once belt table is cleaned, remove all "RED" barricade 5. cubical explosion, area not clear of personal. 5 Make sure area is clear of personal and stand to the side of tape from belt table area and all the way down to the caught in rotating equipment, causing injury to personal. cubical with proper ppe on while throwing in switchgear. bottom floor. Notify the chief operator that cleaning is reinstall all machine guarding on rotating equipment. complete and that you are going to remove the locks and engage the switchgear to return belt to service. after all rotating equipment guards have been installed.

3 JOB SAFETY HAZARD ANALYSIS PAGE 2 WRITTEN BY: MIKE WESSON, R. GRIMES, S. HUNTER TOPIC: CLEANING UNDER CONVEYOR BELTS. APPROVED BY: ED POLLARD 1. Proper use of equipment shall be used such as 1. Not using proper equipment to clean moving conveyor belt. 1. Employees assigned to clean in close proximity to a moving skid steer loader, long handle shovel or hoe. conveyor must be trained in safe methods. 2. Clean out from under moving conveyor. 2. Loose clothing, long hair, jewelry, getting entangled in moving 2. Employees shall always face in the direction the belt is moving. conveyor parts, anything caught in moving conveyor shall be let go and pull the trip cord or push the nearest stop button. 3. If using an air lance to remove material from under belt 3. Injury and property damage could occur if the three foot clearance is not 3. Supervisor will verify that the 3 foot distance can be maintained a lock out may not be required as long as you maintain a maintained. and if not, then the belt will be locked out for cleaning. 3' ( 3 foot) distanced from belt and table. This 3 foot area is from the end of the air lance to the belt. 4. Notify the chief operator that cleaning is completed. 4. No hazard 4. None.

4 JOB SAFETY HAZARD ANALYSIS PAGE 3 AREA: SHIPPING UNIT# 1 REVISED: 4/1/2008 WRITTEN BY: MIKE WESSON, S. HUNTER, F. ESPARZA TOPIC: CLEANING PRODUCT CHUTES APPROVED BY: ED POLLARD 1. Shut down equipment, and lockout and tag out : 1. Cubical explosion. 1. Stand to side of cubical with proper ppe on while throwing out reclaim elevators, and conveyors and hydraulic on the switchgear. splitters. ( See lockout procedures. ) 2. Push start button in control room and field switch to 2. Shock from field switch, bare wires, cracked field switch box. 2. Wear proper ppe : work gloves. Notify supervisorif needed verify power source is reenergized. repairs are needed. 3. Pull doors on chutes as needed for cleaning. 3. Pinch points, sharp edges on doors, heavy build up on doors falling out. 3. Wear proper ppe. Body positioning, watch for possible falling strain on body opening doors. build up. ( work gloves.) 4. Clean chute with proper tools for the job. 4. Having the wrong cleaning tools for the task., pinch points, slip and fall. 4. Use of proper cleaning equipment, body positioning, wearing of proper ppe. Air hammer, and sludge hammer. And using work gloves. 5. After build up and plugage has been removed from 5. Pinch points, slip, trip and fall, doors leaking causing slip hazard. 5. Wear proper ppe, maintain three points of contact at all times. chutes, check pluggage from falling debris through the plugging system down below area that was just cleaned. seal doors to prevent spillage, keep hands clear of pinch points. rest of the system, And close doors. check for build up that was not removed from clean chutes. 6. Notify chief operator that system is clean and chief 6. Employees not clear of equipment, cleaning tools not removed from 6. Verify that equipment is ready to returned back to service. operator does a visual inspection of plant to make sure chutes, doors not closed. cleaning equipment has been removed, personal is clear and that plant is ready to be started up. 7. Remove safety lock from switchgear and reenergize 7. Cubical explosion. 7. Stand to side with proper ppe on while throwing in switchgear. equipment for start up. ( see lockout procedures) ( Hard hat AND SAFETY GLASSES.)

5 JOB SAFETY HAZARD ANALYSIS PAGE 4 WRITTEN BY: MIKE WESSON, R. EDWARDS, F.ESPARZA, R.SVEUM TOPIC: CLEANING TRUCK PITS. APPROVED BY: ED POLLARD 1. Barricade area with red tape and hang tags on danger 1. Slippery conditions. 1. Insure footing at all times. tags on tape. 2. Pump water out of pit. 2. Electrical shock from start and stop switch box. 2. Check for bare wires and crack in switch box. 3. Open man way covers and install barricades over hole 3. Back strains, pulled muscles, personal falling into man way hole. 3. Correct body positioning, barricade of openings. openings. watchman must be present at all times with man ways open. 4. Perform atmospheric test of truck pit at both end of 4. Falling into opening, snuffer out of date, out of calibration. 4. Insure footing, make sure gas meter is calibrated correctly, scale and at different levels. Battery is dead. and is up to date. Also that battery are charged. 5. Issue confine space permit as per. Confine space 5. No hazard 5. None matrix for approval. 6. Get cleaning equipment set up to enter truck pit. 6. Slip, trip, and fall, pinch points, back strain. 6. Keep eyes on task, insure footing, correct body positioning. 7. Put on safety harness hook up life line, face shield, 7. Slip, trip, and fall, pinch points, back strain. Not having proper ppe on. 7. Keep eyes on task, insure footing, correct body positioning. enter truck pit and starting washing out pit and / or water or debris in eyes. wear proper ppe. plus Face shield, safety harness. vacuming pit out. life line hooked to safety harness. 8. When finished cleaning pit, exit pit and remove 8. Slip, trip, and fall, pinch points, back strain. 8. Keep eyes on task, insure footing, correct body positioning. cleaning equipment and replace man way covers. get help with equipment. also remove barricade tape. 9. Return scale to service. 9. No hazard 9. None.

6 JOB SAFETY HAZARD ANALYSIS PAGE 5 WRITTEN BY: MIKE WESSON,R. SVEUM, S. HUNTER, F. ESPARZA TOPIC: CLEAN CONVEYOR MAGNETS. APPROVED BY: ED POLLARD 1. Shut down conveyor or conveyors that are under 1. No hazard 1. None. magnet that are being cleaned. 2. Lockout and tagout conveyors where magnets are to 2. Cubical explosion. 2. Stand to side of cubical with Hard hat and safety glasses on be cleaned. ( SEE LOCK OUT PROCEDURES ) while throwing out switchgear out. 3. Check push start button in control room and field 3. Electrical shock. Bare wires, damaged field box. 3. Wear proper ppe : work gloves on Notify supervisor of switch button. repairs needed. 4. Place mat under magnet to caught debris and shut off 4. Pinch points. 4. Wear proper ppe. Work gloves. magnet. 5. Scrape off magnet and remove mat with debris on it, 5. Falling debris, electrical shock, splinters from fine pieces of debris. 5. Body positioning, wear proper ppe, notify supervisor of then start magnet back up. needed repairs. 6. Notify chief operator job is completed and remove 6. No hazard 6. None. safety lock. 7. Return equipment back to service. 7. Cubical explosion. 7. Stand to side with hard hat and safety glasses on throwing switchgear in.

7 JOB SAFETY HAZARD ANALYSIS PAGE 6 DATE: 4/2/2008 AREA: SHIPPING UNIT # 1 REVISED: 4/2/2008 WRITTEN BY: MIKE WESSON, R. ROBERTS, V. MANGHRAM TOPIC: FILL OIL TANK ON RECLAIMER APPROVED BY: ED POLLARD 1. Raise both chains on reclaimer. 1. Damage to the chain or flites. 1. Insure both chains do not hit each other. 2. Travel reclaimer to south end of storage building. 2. Chain hitting south wall. 2. Make sure chains are high enough to clear south wall. 3.Shut down reclaim by pushing stop button. 3. No hazard. 3. None 4. Walk down stairs to oil tank. 4. Slip, trip, and fall. 4. Maintain three points of contact at all times. 5. Hook up oil hose to reclaimer oil tank. 5. Pinch points. 5. Wear work gloves. 6. Fill oil tank by opening air valve. 6. Pinch points, overflow of oil tank. 6. Wear work gloves, watch level on oil tank to insure oil does not spill on the ground. 7. When oil tank is fill, remove hose from fitting and 7. Pinch points, hose in roadway being run over, 7. Wear work gloves and roll up hose out of roadway. and return hose to oil tank. 8. Return reclaimer to service. 8. Hit south wall, chains hitting together. 8. Insure reclaimer does not hit employees, or obstructions.

8 JOB SAFETY HAZARD ANALYSIS PAGE 7 AREA: SHIPPING unit # 1 REVISED: 4/1/2008 WRITTEN BY: MIKE WESSON, R.EDWARDS, R.SVEUM, F. ESPARZA TOPIC: clean lump breaker. APPROVED BY: ED POLLARD 1. Shut down 420 conveyor feed belt, high speed elevator 1. No hazard. 1. None. and lump breaker. 2. Lock out - tag out 420 conveyor, high speed elevator 2. Cubical explosion. 2. Stand to side cubical with hard hat and safety glasses on, and lump breaker. ( see lock out procedures ) while throwing switchgear out. 3. Check control room push button and field switch. 3. Starting equipment back up, bare wires, electrical shock from field switch. 3. Make sure correct equipment is locked out. Notifty supervisor to verify equipment is locked out. of any electrical problems that need repaired. 4. Climb stairs and open door and use gas meter for 4. Pinch points, slip, trip, and fall. Gas meter not calibrated, out of date, 4. Wear work gloves, check gas meter for calibration, and date. atmospheric testing. dead battery. keep gas meter on battery charger. Maintain three points of contract at all times. 5. Fill out permits for confine space, and safe work permit. 5.. No hazard 5.. None. 6. Open lump breaker for cleaning or repairs. 6. Pinch points, wrong tools for job 6. Wear work gloves, watch for pinch points, use right tools for job. 7. Clean out or repair lump breaker. 7. Pinch points, wrong tools for job, log could roll. 7. Wear work gloves, use right tools for job. 8. When cleaning is complete, close door and notify 8. Equipment not ready to return to service, door not closed. 8. Make sure cleaning equipment has been removed and that chief operator job has been completed, chief operator cleaning equipment not removed. door has been closed. verifies equipment is ready to return to service. 9. Remove safety locks and return equipment back to 9. Cubical explosion, 9. Stand to side with proper ppe on while throwing switchgear service. Close out permits. back in.

9 JOB SAFETY HAZARD ANALYSIS PAGE 8 DATE: 4/2/2008 AREA: SHIPPING UNIT # 1 REVISED: 4/2/2008 WRITTEN BY: MIKE WESSON, R. ROBERTS, V. MANGHRAM TOPIC: MOVE RECLAIMER TO MAINTENANCE AREA APPROVED BY: ED POLLARD 1. Raise both chains on reclaimer. 1. Damage to the chain or flites. 1. Insure both chains do not hit each other. 2. Travel reclaimer to south end of storage building. 2. Chain hitting south wall. 2. Make sure chains are high enough to clear south wall. and lower main chain in maintenance area. 3.Shut down reclaim by pushing stop button. 3. No hazard. 3. None 4. Walk down stairs and push in emergency stop switch. 4. Slip, trip, and fall. 4. Maintain three points of contact at all times. 5. Notify chief operator that reclaimer is for maintenance. 5. No hazard. 5. None.

10 JOB SAFETY HAZARD ANALYSIS PAGE 9 DATE: 4/3/2008 AREA: SHIPPING UNIT # 1 REVISED: 4/3/2008 WRITTEN BY: MIKE WESSON, V. MANGHRAM, R. ROBERTS TOPIC: CHANGING PRODUCTS AT UNIT # 1 APPROVED BY: ED POLLARD 1. Drain system for change over. Run system until empty, 1. Contamination of product. Dust or product in eyes. 1. Empty all product from system. Wear proper ppe, drain truck surge bin and fines bin. safety glasses. 2. Get instructions from chief as to which product plant is 2. Feeding wrong product to shipping unit. Contamination of product. 2. Get correct instructions from chief operator. switching to. And which warehouse plant will be pulling product from. 3. Climb stairs to diverter floor to control panel. 3. Slip, trip and fall. 3. Maintain three points of contact at all times. Insure footing. 4. Open control box and move diverter or diverters 4. Pinch points, possible hydraulic leak. 4. Wear proper ppe, and notify supervisor if any leaks occur. levers to correct position. And verify limit switches ( Work gloves and safety glasses.) have made proper contact. 5. Notify chief operator that shipping unit is ready to 5. No hazard 5. None start up. 6. When unit starts up, check to make sure product is 6. Slip, trip, and fall. 6. Insure footing, and keep area clean. only feeding to shipping unit # 1.

11 JOB SAFETY HAZARD ANALYSIS PAGE 10 DATE: 4/3/2008 AREA: SHIPPING UNIT # 1 REVISED: 4/3/2008 WRITTEN BY: MIKE WESSON, R. GRIMES, E. CHATTIN TOPIC: CLEAN RAIL BIN AT UNIT # 1 APPROVED BY: ED POLLARD 1. Empty out rail bin into railcar. 1. Car loader falling off railcar, pinch points, 1. Wear proper ppe: safety harness with life line, work gloves. 2.GO to MCC room and lock out the 445 conveyor belt. 2. Cubical explosion, belt starting up, slip, trip, and fall. 2. Maintain three points of contact at all times. Stand to side ( SEE LOCK OUT PROCEDURES ) of cubical when throwing out switchgear with proper ppe on : safety glasses, and hard hat. Verify conveyor lock out. 3. Walk up stairs and open doors, do atmospheric test of 3. Slip, trip, and fall, Gas meter out of calibration, or out of date, battery 3. Maintain three points of contact at all times. Wear proper rail bin at different levels. on gas meter may be dead. Pinch point from opening doors. ppe : work gloves. Check out gas meter before leaving control room. 4. Fill out confine space permit and have permit approved 4. No hazard 4. None by management. 5. Clear tracks 21 & 22, and put derailers on both tracks 5. Slip, trip, and fall. 5. Insure footing on ground at all times and watch for trip hazards. and lock them out. 6. Enter rail bin and start cleaning bin out. By dry cleaning 6. Not wearing proper ppe, pinch points, slip and fall. No watch man. 6. Wear proper ppe : safety harness and life line hooked to or washing rail bin out. beam or pad eye. Have watch man outside of confine space. Insure proper footing at all times. 7. After cleaning out bin, remove cleaning equipment 7. Slip, and fall, pinch points. 7. Maintain three points of contact at all times and wear work from rail bin and exit bin. gloves. 8. Notify chief operator rail bin is clean, after chief 8. Slip, trip, and fall. Pinch points, cubical explosion. 8. Maintain three points of contact, wear work gloves, stand to verifies bin is clean, close doors and unlock 445 side while throwing in switchgear with safety glasses and conveyor and throw in switchgear. hard hat on.

12 JOB SAFETY HAZARD ANALYSIS PAGE 11 DATE: 4/3/2008 AREA: SHIPPING UNIT # 1 REVISED: 4/3/2008 WRITTEN BY: MIKE WESSON, E. CHATTIN, R. GRIMES TOPIC: CLEAN TRUCK BIN APPROVED BY: ED POLLARD 1. Empty out system. 1. No hazard 1. None 2.Shut down and lock out blender elevator, screens 2. Cubical explosion. 2. Stand to side of cubical with hard hat and safety glasses on. ( see lock out procedures.) while throwing switch gear out. 3. Push button on control panel and field switch to 3. Serious injury could occur if equipment starts up. Possible shock hazard. 3. Check field switch for cracks and bare wires, wear proper verify equipment will not start up. Bare wires. ppe : work gloves and notify supervisor of any electrical repairs needed. 4. Climb stairs, open doors and atmospheric test truck 4. Slip, trip, and fall, calibration of gas meter off, gas meter out of date, 4. Maintain three points of contact at all times. Check gas bin. dead battery. Build up falling out of door hitting employees. pinch points. before leaving control room. Stand to side while opening door. Wear safety work gloves. 5. Fill out safe work permit, and entry permit, have 5. No hazard. 5. None. permit approved by management. 6. Barricade truck scale with red barricade tape and 6. Employees walking into working area and lumps and debris falling on 6. Barricade area off with red tape and hanging danger tags. and hang danger tags. employees and contractors. 7. Open truck diverter and start washing truck bin out. 7. Not wearing proper ppe, slip, and fall, water and debris splashed into face. 7. Wear proper ppe for job. Safety harness and life line stripped 0r air hammer truck bin out. to beam or pad eye. Safety glasses, face shield, work gloves. 8. After truck bin has been cleaned and inspected, 8. Slip, trip, and fall, pinch points, cleaning equipment left in truck bin. 8. wear work gloves, insure of footing. Make sure cleaning remove hose and cleaning equipment and close doors. equipment removed from bin. 9. Unlock elevator and screens, return to service. 9. Cubical explosion. 9. Stand to side of cubical, with hard hat, safety glasses on while throwing switchgear in.

13 JOB SAFETY HAZARD ANALYSIS PAGE 12 DATE: 4/3/2008 AREA: SHIPPING UNIT # 1 REVISED: 4/3/2008 WRITTEN BY: MIKE WESSON, V. MANGHRAM, R. ROBERTS. TOPIC: CLEAN RIBBON BLENDER APPROVED BY: ED POLLARD 1. Empty out system for cleaning. 1. No hazard 1. None 2. Shut down ribbon blender elevator, screens, and ribbon blender. Valve out oil. ( double block and bled ) 2. Hot oil line, burned by hot oil. 2. Wear proper ppe : work gloves, face shield, rain coat. 3. Lock out and tag out : ribbon blender elevator, screens 3. Cubical explosion. Burned by hot oil. Pinch points. 3. Stand to side of cubical with proper ppe on while throwing out and ribbon blender and oil line. switchgear. Wear proper ppe : work gloves, ( see lock out tag out procedures.) 4. Check control room start button and field switch to 4. Equipment starting up. electrical shock, 4. Verify equipment is locked out, notify supervisor if any To make sure equipment will not start up. electrical repairs are needed. 5. Walk up stairs and pull door off of top of blender. 5. Slip, trip and fall hazards, pinch points. 5. Maintain three points of contact at all times. Wear proper ppe, work gloves and safety glasses. 6. Clean ribbon blender. 6. Slip and fall, pinch points, debris in eyes. 6. Insure footing, wear proper ppe, work gloves, safety glasses. 7 When finished, install doors back on blender. 7. Slip, trip and fall hazards, pinch points. 7. Insure footing, wear proper ppe, work gloves, safety glasses. 8. Remove lock from oil valve. Notify chief operator job is 8. Hot oil may get burned. 8. Close bleed valve on oil and open oil to blender. completed. remove safety locks from equipment or lock box. 9. Return equipment to service. 9. Cubical explosion. 9. Stand to side of cubical with proper ppe on while throwing in. switchgear. Safety glasses and hard hat.

14 JOB SAFETY HAZARD ANALYSIS PAGE 13 DATE: 4/3/2008 AREA: SHIPPING UNIT # 1 REVISED: 4/3/2008 WRITTEN BY: MIKE WESSON, R. ROBERTS, V. MANGHRAM, TOPIC: CLEAN HIGH SPEED BOOT E. CHATTIN APPROVED BY: ED POLLARD 1. Empty out elevator. 1. No hazard. 1. None 2. Lock out and tag out high speed elevator, and 2. Cubical explosion. 2. Stand to side of cubical with hard hat and safety glasses on 423 c0nveyor belt. ( SEE LOCK OUT PROCEDURES) while throwing out breaker. 3. Push button on control room panel and field switch to 3. Cracked field switch, bare wires, electrical shock 3. Check field switch for damage, wear work gloves, notify verify equipment will not start up. supervisor of any electrical repairs needed. 4. Fill out safe work permit and have maintenance open 4. Pinch points, slip, trip, and fall. 4. Wear proper ppe : work gloves, elevator door for cleaning. 5. Clean out elevator boot by shoveling, or washing. 5. Slip, trip, and fall, pinch points, splashing debris into eyes. 5. Insure proper footing, wear work gloves, If washing out boot, wear face sheild. 6. Close doors on elevator after cleaning out boot. 6. Pinch points, slip, trip, and fall. 6. Wear work gloves, Insure proper footing. 7. Notify chief operator that elevator is cleaned out and 7. No hazard 7. None doors are closed. 8. Remove safety locks and return elevator and conveyor 8. Cubical explosion, 8. Stand to side of cubical with hard hat and safety glasses on back to service. while throwing in breaker.

15 JOB SAFETY HAZARD ANALYSIS PAGE 14 DATE: 4/3/2008 AREA: SHIPPING UNIT # 1 REVISED: 4/3/2008 WRITTEN BY: MIKE WESSON, R. ROBERTS, V. MANGHRAM, TOPIC: CLEAN R.B. ELEVATOR BOOT E. CHATTIN APPROVED BY: ED POLLARD 1. Empty out elevator. 1. No hazard. 1. None 2. Lock out and tag out ribbon blender elevator, and 2. Cubical explosion. 2. Stand to side of cubical with hard hat and safety glasses on 443 conveyor belt. ( SEE LOCK OUT PROCEDURES) while throwing out breaker. 3. Push button on control room panel and field switch to 3. Cracked field switch, bare wires, electrical shock 3. Check field switch for damage, wear work gloves, notify verify equipment will not start up. supervisor of any electrical repairs needed. 4. Fill out safe work permit and have maintenance open 4. Pinch points, slip, trip, and fall. 4. Wear proper ppe : work gloves, elevator door for cleaning. 5. Clean out elevator boot by shoveling, or washing. 5. Slip, trip, and fall, pinch points, splashing debris into eyes. 5. Insure proper footing, wear work gloves, If washing out boot, wear face sheild. 6. Close doors on elevator after cleaning out boot. 6. Pinch points, slip, trip, and fall. 6. Wear work gloves, Insure proper footing. 7. Notify chief operator that elevator is cleaned out and 7. No hazard 7. None doors are closed. 8. Remove safety locks and return elevator and conveyor 8. Cubical explosion, 8. Stand to side of cubical with hard hat and safety glasses on back to service. while throwing in breaker.

16 JOB SAFETY HAZARD ANALYSIS PAGE 1 5 DATE: 4/3/2008 AREA: SHIPPING UNIT # 1 REVISED: 4/3/2008 WRITTEN BY: MIKE WESSON, R. ROBERTS, V. MANGHRAM, TOPIC: CLEAN BLENDER GRID. E. CHATTIN APPROVED BY: ED POLLARD 1. Shut off flow of product to # 1 shipping unit. 1. No hazard 1. None 2. Climb stairs to ribbon blender grid 2. Slip, trip, and fall. 2. Maintain three points of contact at all times. 3. Use chain hoist to lift flip off of grid. 3. Pinch points. 3. Wear safety work gloves. Watch hands while pulling chain on chain hoist. 4. Clean lumps for grid using shovel. 4. Pinch points. 4. Wear safety work gloves. 5. Close flip on grid using chain hoist. 5. Pinch points. 5. Wear safety work gloves. Watch hands while pulling chain on chain hoist 6. Walk back down to control room and start product 6. Slip, trip, and fall. 6. Maintain three points of contactat all times. flow back to plant.

17 JOB SAFETY HAZARD ANALYSIS PAGE 16 AREA: SHIPPING # 1 REVISED: 4/1/2008 WRITTEN BY: MIKE WESSON, S. HUNTER, R. SVEUM TOPIC: STARTING RECLAIM HOPPER. APPROVED BY: ED POLLARD 1. CHECK OUT RECLAIM HOPPER FOR TRASH AND METAL. 1. SLIP AND FALL OFF LADDER CAUSING INJURY. 1. MAINTAIN THREE POINTS OF CONTACT AT ALL TIMES. SHALL KEEP HANDS FREE OF MATERIAL. 2.MAKE SURE RECLAIM CONVEYOR IS RUNNING BEFORE STARTING RECLAIM HOPPER. 2. No hazard 2. NONE 3. START RECLAIM HOPPER. 3. POSSIBLE SLIP AND FALL CAUSING INJURY, AND POSSIBLE ELECTRICAL 3. MAKE VISUAL CHECK OF WALKING CONDITIONS BEFORE Shock FROM START PUSH BUTTON. STARTING HOPPER. KEEP AREA CLEAN OF WET OR LOOSE PRODUCT. MAKE VISUAL INSPECTION OF FIELD SWITCH FOR CRACKS AND BARE WIRES. KEEP AREA CLEAN. 4.CHECK THE RECLAIM HOPPER FOR LEAKS AT SKIRTING, 4. LOSE YOUR FOOTING ON LOOSE OR WET PRODUCT. AND ALIGNMENT OF RECLAIM HOPPER BELT AND CONVEYOR. 4. EYES ON TASK, CHECK AREA BEFORE PROCEEDING AND KEEP AREA CLEAN. GOOD HOUSE KEEPING. 5. MOUNT LOADER AND PUT ON SAFETY BELT. 5. SLIP AND FALL CAUSING INJURY. 5. FACE EQUIPMENT AND MAINTAIN THREE POINTS OF CONTACT AT ALL TIMES. HANDS SHALL BE FREE OF MATERIAL. 6. DUMP BUCKET OF RECLAIM PRODUCT INTO HOPPER. 6. SKIRTS LEAKING, HOPPER BELT OUT OF ALIGNMENT. COULD PUSH 6. RECHECK HOPPER FOR LEAKS AT SKIRTING AND RECLAIM CONVEYOR BELT OUT OF ALIGNMENT AND CAUSE SPILLAGE OR POSSIBLE BELT FOR POSSIBLE MISALIGNMENT. DAMAGE. 7. IF ANY PROBLEMS EXIST RADIO CHIEF OPERATOR 7. SPILLAGE AND / OR DAMAGE TO EQUIPMENT. 7. CALL SUPERVISOR FOR REPAIRS AND CLEAN AREA UP. AFTER SHUTTING DOWN RECLAIM HOPPER.

18 JOB SAFETY HAZARD ANALYSIS PAGE 1 7 WRITTEN BY: MIKE WESSON, R. ROWE, R. BEAVERS TOPIC: RECLAIMER - DRESSING PILE APPROVED BY: ED POLLARD 1. Notify chief operator to speed up reclaimer to dress 1. No hazard. 1. None a pile of product. 2. Make sure main chain raised before moving reclaimer. 2. Running into new pile of product., damage to reclaimer. 2. Make sure main chain is raised higher than new pile. 3. Proced to new pile of product. 3. Product on track causing skewing. 3. Reclaim operator check both rails before moving reclaimer to new pile. 4. Lower main chain onto new pile, traveling north to 4. Dropping main chain to deep into pile, causing reclaimer to skew. south end dropping main chain a little at a time to pull Or burying 2158 conveyor belt. 4. Eyes on task, being carfull not to drop main chain to deep. product off the top of pile onto the 2158 conveyor belt. 5. Call chief operator to slow down speed of reclaimer. 5. Burying 2158 conveyor belt and dog house. 5, Slow reclaimer down.

19 JOB SAFETY HAZARD ANALYSIS PAGE 1 8 WRITTEN BY: MIKE WESSON, HUGH CARROLL TOPIC: DRAINING OIL TANK BARRICADE APPROVED BY: ED POLLARD 1. Check for any spilled coating oil inside barricade, 1. Environmental hazard 1. Notify supervisor of coating oil inside barricade. that maybe needed to be removed. 2. Remove lock on drain valve and open valve to start 2. Pinch points. 2. Wear work gloves while turning drain valve to open position. draining water out of barricade area. 4. After area is drained, close drain valve and lock out 4. Pinch points. 4. Wear work gloves while turning drain valve to closed position. drain valve.

20 JOB SAFETY HAZARD ANALYSIS PAGE 1 9 WRITTEN BY: MIKE WESSON, HUGH CARROLL TOPIC: CLEAN COATING OIL TANK BARRICADE APPROVED BY: ED POLLARD 1. Check for any spilled coating oil inside barricade, 1. Environmental hazard 1. Notify supervisor of coating oil inside barricade. that maybe needed to be removed. 2. Remove lock on drain valve and open valve to start 2. Pinch points. 2. Wear work gloves while turning drain valve to open position. draining water out of barricade area. 2. After barricade water level is pulled down, remove 2. Slip, and fall. 2. Insure footing at all times, wear work gloves. any trash that has gotten in side of barricade. 4. After area is clean and drained, close drain valve 4. Pinch points. 4. Wear work gloves while turning drain valve to closed position. and lock valve back out.

21 JOB SAFETY HAZARD ANALYSIS PAGE 2 0 WRITTEN BY: MIKE WESSON, R. ROWE, R. BEAVERS TOPIC: VALVING IN OIL SYSTEM APPROVED BY: ED POLLARD 1. Go around to oil tank. 1. Slip, trip, and fall. 1. Insure footing at all times. 2. Open outlet and return valves on oil tank. 2. Slip, trip, and fall. Strain muscles, pinch points. 2. Wear work gloves, Insure body positioning, Get help if needed. 3. Valve in product oil pump. 3. Slip, trip, and fall. Strain muscles, pinch points. 3. Wear work gloves, Insure body positioning, Get help if needed. 4. Start pump and check for leaks. 4. Shock hazard, 4. wear work gloves, Notify supervisor of any electrical repairs needed. 5. Go back to control room and set ratio for tons per hour. 5. Slip, trip, and fall. 5. Insure footing at all times.

22 JOB SAFETY HAZARD ANALYSIS PAGE 2 1 WRITTEN BY: MIKE WESSON, R. ROWE, R. BEAVERS TOPIC: cleaning inside rail scale area. # 1 APPROVED BY: ED POLLARD 1. Lock out tracks # 21 and # Slip, trip, and fall. 1. Insure footing at all times. 2. Fill out safe work permit and have maintenance 2. No hazard 2. None remove covers to wash out scale. 3. Put up red barricade tape up around scale area and 3. Slip, trip, and fall. 3. Insure footing at all times. hang up danger tags on red barricade tape. 4. Hook up hose for washing scale and start 4. Water and debris splashing into face and eyes. Slip, trip, and fall. 4. Wear proper ppe : safety glasses and face shield. washing out scale. Insure balance and footing working a round scale area. 5. After scales have been cleaned out, Notify Chief 5., No hazard 5. None operator scales are clean and inspected. 6. Have maintenance replace scale covers. 6. No hazard 6. None 7. After scale covers have been reinstalled, remove 7. Slip, trip, and fall. 7. Insure footing at all times. barricade tape and remove personal safety locks.

23 JOB SAFETY HAZARD ANALYSIS PAGE 2 2 WRITTEN BY: MIKE WESSON, R. ROWE, R. BEAVERS. TOPIC: CLEAN TRUCK / RAIL DIVERTER VALVING OUT HYDRAULIC LINES ARE NOT IN SERVICE AT THIS TIME.( FUTURE INSTALLATION) APPROVED BY: ED POLLARD 1. Get proper tools for cleaning rail & truck diverter : 1. Slip, trip, and fall 1. Be aware of footing, and body positioning. rail bar, sledge hammer, air hammer. 2. Go to # 1 MCC room and lock out ribbon blender 2. Slip, trip, and fall, cubical explosion. 2. Maintain three points of contact at all times. Stand to side elevator. of cubical with proper ppe on while throwing switchgear in. ( hard hat, and safety glasses ) 3. Climb stairs to truck and rail diverter in the rail tower. 3. Slip, trip, and fall 3. Maintain three points of contact at all times. 4. Valve out, lock out, and bleed down hydraulic lines. 4. Diverter throwing from side to side, crushing body parts, pinch points. 4. Locking out and bleeding down hydraulic line and system. wear work gloves. 5. Open door on diverter. 5. Pinch points, build up falling out of door. 5. Wear work gloves, Insure proper body positioning. Be aware of potential hazards. 6. Beat out and rod out chute. 6. Pinch points, build up falling out of door. 6. Wear work gloves, Insure proper body positioning. Be aware of potential hazards. 7. When finished with one side, unlock hydraulic lines, 7. Diverter throwing from side to side, crushing body parts, pinch points. 7. Locking out and bleeding down hydraulic line and system. throw diverter to clean to other side of diverter. Valve wear work gloves. out, lock out and bleed down system. 8. When job is completed, unlock and valve hydraulic 8. Slip, trip, and fall, cubical explosion, pinch points. 8. Maintain three points of contact at all times. Stand to side system back in. And unlock ribbon blender elevator. of cubical with proper ppe on while throwing switchgear in. ( hard hat, and safety glasses, work gloves.)

24 JOB SAFETY HAZARD ANALYSIS PAGE 2 3 WRITTEN BY: MIKE WESSON, R. ROWE, R. BEAVERS TOPIC: RAILCAR LOADING # 1 APPROVED BY: ED POLLARD 1. Gather safety equipment, : safety harness, work gloves 1. Damaged safety harness. 1. Replace if safety harness is damage. 2. Raise derailers and lock out both tracks. 2. Derail railcars and or locomotive. 2. Make sure derailer are working and track is clear. 3. Unpin cars potter dogs, and spot railcar. 3. Pinch points, slip, trip, and fall. 3. Wear work gloves, be ware of body positioning and Insure footing at all times. 4. Check bottom doors and install tags, proceed to 4. Slip, trip, and fall, pinch points. 4. Wear work gloves, maintain three points of contact at all loading platform. times. 5. Put on safety harness and hook up to lanyard. 5. No hazard. 5. None 6. Step out on to top of railcar and open doors, check 6. Slip, trip, and fall, strain muscles, pinch points. 6. Be aware of surrounding, body positioning, wear work gloves. compartments for open doors, damage, and foreign materials. 7. Turn on fail safety switch. 7. Slip, trip, and fall. 7. Insure footing at all times. 8. Put loading chute in railcar and start filling railcar 8. Back strain, pinch points, slip, trip, and fall. 8. Correct body positioning, wear work gloves, get help with compartment to proper weight. chutes if needed. 9. Close and tag doors. 9. Back strain, pinch points, slip, trip, and fall. 9. Correct body positioning, wear work gloves, get help with doors if needed. 10. Turn off fail safe switch and raise chutes. 10. Slip, trip, and fall., pinch points. 10. Insure footing at all times. Wear work gloves.

25 JOB SAFETY HAZARD ANALYSIS PAGE 2 4 WRITTEN BY: MIKE WESSON, R. BEAVERS, R ROWE TOPIC: LOADING TRUCKS AT # 1 APPROVED BY: ED POLLARD 1. Walk up one flite of stairs and back down to loading 1. Slip, trip, and fall. Low head room. 1. Maintain three points of contact at all times. platform. Watch clearance. 2. Drop rope down, and have truck driver place scan card 2. Doors not being opened up on top of truck when pulling under load out and 2. Have truck drivers insure that there top doors are open before on rope, car loader scans card and truck driver pulls doors hitting walk way. Or the trailer bottom doors or tail gate doors are pulling under loading station. And that there bottom or on to scale to be weighed. not closed. back tail gates are closed. 3. Spot truck for loading, open slide gate and start loading 3. Hitting employee or obstruction, spillage from over the side of truck, 3. Insure trucks are lined up under loading chutes and if the truck, signal truck driver with your light system, spillage in road way, causing a slipping hazard for employees and trailer is not lined up, have truck driver move trailer over. move truck front to middle and back to middle until vehicles. Hydraulic pump failure causing slide gates not to close, and If hydraulic system fails, truck loader is to notify chief truck weigh is right. emptying truck bin on scale causing more spillage and unsafe conditions. operator to shut system down. 4. Catch sample of product being loaded. 4. Pinch points. 4. Beware of pinch points. 5. After truck is loaded, close slide gate and use air 5. Product being blown into eyes, slip and fall from product on the ground. 5. wear safety glasses or goggles'. Insure footing at all times. lance to blow off any spillage on top of truck. 6. Signal truck driver with signal light system when he 6. Spillage on scale if truck driver leaves before slide gates are closed. 6. Make sure slide gates are closed before signaling truck is loaded and can pull out of loading area. Slip, trip, and fall hazards. driver to pull off scale. Have standard procedure that truck driver blows horn before pulling off scales.

26 JOB SAFETY HAZARD ANALYSIS PAGE 2 5 WRITTEN BY: MIKE WESSON, R. ROWE, R. BEAVERS. TOPIC: PLANT INSPECTION # 1 APPROVED BY: ED POLLARD 1. Shut down the shipping unit. 1. No hazard 1. None 2. Put on proper ppe : hard hat, safety glasses, 2. No hazard 2. None hearing protection. 3. Walk up to the top of truck tower and master splitter 3. Slip, trip, and fall 3. Maintain three points of contact at all times. and high speed elevator. 4. Walk down to screen floor and check screens, 4. Slip, trip, and fall 4. Maintain three points of contact at all times. splitters and chutes. 5. Walk over to rail tower and check out ribbon blender, 5. Slip, trip, and fall 5. Maintain three points of contact at all times. elevator and discharge chutes. 6.Maintain three points of contact at all times. 6. Cross over to truck tower and check out splitters, and 6. Slip, trip, and fall chutes. 7. Maintain three points of contact at all times. 7. Walk down to transfer floor and check out your 7. Slip, trip, and fall 423 conveyor, and 425 conveyor belts, 2160 belt and magnet. Also splitter and chutes 8. Walk down to the 420 conveyor belt and lump breaker. 8. Slip, trip, and fall 8. Maintain three points of contact at all times. 9. Walk down to storage building and check 06 conveyor, 9. Slip, trip, and fall, being hit by pay loader. 9. Be aware of footing at all times, Notify chief at # 2 shipping and magnet. before entering storage building.

27 JOB SAFETY HAZARD ANALYSIS PAGE 2 6 WRITTEN BY: MIKE WESSON, R. BEAVERS, R. ROWE TOPIC: INSPECTION OF G-3 & W.H. # 1 APPROVED BY: ED POLLARD 1. Call chief operator at # 2 shipping to get clearance 1. Not having clearance to enter warehouses, getting hit by pay loaders. 1. Call chief operator to get approval to enter warehouses. to enter G-3 and # 1 warehouses. Making sure chief operator gets in touch with pay loader operator to let loader operator know you will be entering warehouses. So loader operator will be on the look out for you. 2. Than entrée must stop at doorway and wait for 2.. Getting hit by pay loader, Slip, trip and fall 2. Get the all clear signal from pay loader operator before pay loader operator to flash there lights to signal entering storage building. Watch for moving equipment. entree that loader operator gives entree the all clear signal that they can enter the warehouse. 3. Make visual inspection magnet on 06 conveyor belt. 3. Getting hit by pay loader, Slip, trip and fall 3. watch for moving pay loaders and equipment. Insure footing. 4. Make visual inspection of 06 conveyor belt, rollers, 4.. Getting hit by pay loader, Slip, trip and fall 3. watch for moving pay loaders and equipment. Insure footing. and tail pulley. 5. Make visual inspection of 05 conveyor belt, rollers, 5. Getting hit by pay loader, Slip, trip and fall 3. watch for moving pay loaders and equipment. Insure footing. and tail pulley. 6. Make visual inspectio of 07 conveyor belt, rollers, 6.. Getting hit by pay loader, Slip, trip and fall 3. watch for moving pay loaders and equipment. Insure footing. and tail pulley. 7. Make visual inspection of reclaim hoppers, and 6.. Getting hit by pay loader, Slip, trip and fall 3. watch for moving pay loaders and equipment. Insure footing. and reclaim hopper conveyors.