TABLE OF CONTENTS - The Mosaic Company the Dryer Spillage Conveyor (005) by pushing the stop button on the panel board. 2. Open and lock the disconnects for the Dryer

1

EQUIPMENT: NORTH FACE SPRAY CIRCULATION PUMP ( 42-016 ) .............................................................................................................................................................3EQUIPMENT: SOUTH FACE SPRAY CIRCULATION PUMP ( 42-017 )..............................................................................................................................................................4EQUIPMENT: ONCE THROUGH WATER RETURN PUMP ( 112 )......................................................................................................................................................................5EQUIPMENT: CHUTE COOLING WATER PUMP ( ) .........................................................................................................................................................................................6EQUIPMENT: DRYER SPILLAGE CONVEYOR ( 005 ).......................................................................................................................................................................................7EQUIPMENT: JEFFERY FEEDER & PRODUCT BIN ( 012 & 143 )......................................................................................................................................................................8EQUIPMENT: AMMONIA COOLER (400) ..........................................................................................................................................................................................................9EQUIPMENT: BFL AMMONIA VAPORIZER (403)...........................................................................................................................................................................................11EQUIPMENT: AIR CHILLER (404) ....................................................................................................................................................................................................................12EQUIPMENT: BAGHOUSE FAN ( 1311 ) ..........................................................................................................................................................................................................13EQUIPMENT: BAGHOUSE SCREW CONVEYOR ( 2111 )................................................................................................................................................................................14EQUIPMENT: DRYER/COOLER EQUIPMENT SCRUBBER (117) ...................................................................................................................................................................15EQUIPMENT: DRYER & COOLER CYCLONES ( 380 & 381 )...........................................................................................................................................................................16EQUIPMENT: DAP WATER COLLECTION TANK ( 154 ) ................................................................................................................................................................................17EQUIPMENT: COOLER BAGHOUSE ( 306 ) .....................................................................................................................................................................................................18EQUIPMENT: 54% ACID STORAGE TANK (502).............................................................................................................................................................................................19EQUIPMENT: 54% ACID STORAGE TANK SPLITTER BOX (650) ..................................................................................................................................................................21EQUIPMENT: AIR PRE-HEATER ( 403 ) ...........................................................................................................................................................................................................22EQUIPMENT: DEFOAMER TANK ( 511 )..........................................................................................................................................................................................................23EQUIPMENT: AMMONIA COOLER (400) ........................................................................................................................................................................................................24EQUIPMENT: BFL AMMONIA VAPORIZER (403)...........................................................................................................................................................................................26EQUIPMENT: AIR CHILLER (1311) ..................................................................................................................................................................................................................27EQUIPMENT: NO.1 54% FEED PUMP (102A)....................................................................................................................................................................................................29EQUIPMENT: NO.2 54% FEED PUMP (102B)....................................................................................................................................................................................................31EQUIPMENT: BFL CONDENSATE PUMP ........................................................................................................................................................................................................33EQUIPMENT: TAIL GAS SCRUBBER CIRCULATION PUMP (116/117) ..........................................................................................................................................................34EQUIPMENT: "A" R/G PRE-SCRUBBER PUMP (119) .......................................................................................................................................................................................36EQUIPMENT: "B" R/G PRE-SCRUBBER PUMP (120) .......................................................................................................................................................................................38EQUIPMENT: "A" ACID SCRUBBER PUMP (120A) .........................................................................................................................................................................................40EQUIPMENT: "B" ACID SCRUBBER PUMP (120B) ..........................................................................................................................................................................................41EQUIPMENT: DEFOAMER PUMP (233A).........................................................................................................................................................................................................43EQUIPMENT: "A" SLURRY PUMP (122A) ........................................................................................................................................................................................................44EQUIPMENT: "B" REACTOR SLURRY PUMP (122B) ......................................................................................................................................................................................45EQUIPMENT: "A" EFFLUENT RETURN PUMP (134A) ....................................................................................................................................................................................46EQUIPMENT: "B" EFFLUENT RETURN PUMP (134B).....................................................................................................................................................................................47EQUIPMENT: CYCLONIC SCRUBBER PUMP(120) .........................................................................................................................................................................................49EQUIPMENT: ONCE THRU WATER PUMP (154).............................................................................................................................................................................................50EQUIPMENT: HYDRAULIC SYSTEM PUMPS (640E-W) .................................................................................................................................................................................51EQUIPMENT: INTREMEDIATE CONVEYOR (016) .........................................................................................................................................................................................53EQUIPMENT: "A" & "B" DEDUSTING SCREEN...............................................................................................................................................................................................55EQUIPMENT: RECYCLE ELEVATOR (102) .....................................................................................................................................................................................................56EQUIPMENT: GRANULATOR (103) .................................................................................................................................................................................................................58EQUIPMENT: LUMPBREAKER (105) ...............................................................................................................................................................................................................60EQUIPMENT: SCREENS FEED ELEVATOR (106) ...........................................................................................................................................................................................61

TABLE OF CONTENTS

2

EQUIPMENT: PROCESS SCREENS (107A-D)...................................................................................................................................................................................................63EQUIPMENT: CAGE MILLS INNER AND OUTER CAGE (108A-D) ................................................................................................................................................................64EQUIPMENT: DRAG FLIGHT CONVEYOR (110).............................................................................................................................................................................................65EQUIPMENT: PRODUCT COOLER (111)..........................................................................................................................................................................................................67EQUIPMENT: PRODUCT ELEVATOR (113).....................................................................................................................................................................................................68EQUIPMENT: PRODUCT CONVEYOR (141)....................................................................................................................................................................................................69EQUIPMENT: FINES CONVEYOR (146)...........................................................................................................................................................................................................70EQUIPMENT: NORTH DAP DISTRIBUTION CONVEYOR (415) .....................................................................................................................................................................71EQUIPMENT: DAP DISTRIBUTION CONVEYOR AND TRIPPER (417/417A) ................................................................................................................................................72EQUIPMENT: PRE-SCREEN RECYCLE CONVEYOR......................................................................................................................................................................................74EQUIPMENT: ROTARY DRYER (104) ..............................................................................................................................................................................................................75EQUIPMENT: COMBUSTION CHAMBER (104-1)............................................................................................................................................................................................76EQUIPMENT: I.D.FAN (116)..............................................................................................................................................................................................................................78EQUIPMENT: DRYER/COOLER EQUIPMENT SCRUBBER (117) ...................................................................................................................................................................79EQUIPMENT: T.G.SCRUBBER (148).................................................................................................................................................................................................................81EQUIPMENT: BURNER BLOWER (153) ...........................................................................................................................................................................................................83EQUIPMENT: CYCLONIC SCRUBBER (310)....................................................................................................................................................................................................84EQUIPMENT: R/G PRE-SCRUBBER .................................................................................................................................................................................................................86EQUIPMENT: BAGHOUSE AIR COMPRESSOR (1313-1-2)..............................................................................................................................................................................88EQUIPMENT: 54% ACID STORAGE TANK AGITATOR (034).........................................................................................................................................................................89EQUIPMENT: REACTOR (501) .........................................................................................................................................................................................................................90EQUIPMENT: 54% ACID STORAGE TANK (502).............................................................................................................................................................................................93EQUIPMENT: 54% ACID STORAGE TANK SPLITTER BOX (650) ..................................................................................................................................................................95

3

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: NORTH FACE SPRAY CIRCULATION PUMP ( 42-016 )EQUIPMENT NUMBER: 42-016DWG. NO.:

PURPOSE: TO SECURE EQUIPMENT FOR MAINTENANCE OR CLEANING.AFFECTED EMPLOYEES: PLANT OPERATORS, OPERATOR TRAINEES AND MAINTENANCE MECHANICS.

WORK STEP TYPE/MAGNITUDE OF ENERGY HAZARDS

1. Stop the North face spray circulation pump( 42-016) by pressing the stop button on the panel board.

2. Open and lock the disconnect for North face spray circulation pump( 42-016) 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 reverse procedures to put the equipment back in service.

1. Electrical/120 volts.


3. Pond water/mildly acidic.

4. None

5. None

1. Accidental start-up.

2. Cubical explosion.

3. Eye/skin irritation

4. No hazard.

5. No hazard.

REVIEWED BY:

AREA SAFETY COMMITTEE YES

CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

4

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: SOUTH FACE SPRAY CIRCULATION PUMP ( 42-017 )EQUIPMENT NUMBER: 42-017DWG. NO.:



1. Stop the South face spray circulation pump( 42-017) by pressing the stop button on the panel board.

2. Open and lock the disconnect for South face spray circulation pump( 42-017) in the Motor Control Center (MCC) with a Production Lock.







4. None

5. None




4. No hazard.

5. No hazard.

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

5

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1EQUIPMENT: ONCE THROUGH WATER RETURN PUMP ( 112 )EQUIPMENT NUMBER: 112DWG. NO.:



1. Stop the Once through water return pump( 112) by pressing the stop button on the panel board.

2. Open and lock the disconnect for Once through water return pump( 112) in the Motor Control Center (MCC) with a Production Lock.






3. Fresh water.

4. None

5. None



3. No hazard

4. No hazard.

5. No hazard.

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

6

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1EQUIPMENT: CHUTE COOLING WATER PUMP ( )EQUIPMENT NUMBER: DWG. NO.:



1. Stop the Chute Cooling Water pump( ) by pressing the stop button on the panl board.

2. Open and lock the disconnect on the Chute Cooling Water pump( ) in the Motor Control Center (MCC) with a Production Lock.






3. Fresh water.

4. None

5. None



3. No hazard

4. No hazard.

5. No hazard.

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

7

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: DRYER SPILLAGE CONVEYOR ( 005 )EQUIPMENT NUMBER: 005 DWG. NO.:



1. 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.

3. Employees working on this equipment will place their personal lock(s) on the equipment designated.




3. None

4. None



3. No hazard.

4. No hazard.

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

8

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: JEFFERY FEEDER & PRODUCT BIN ( 012 & 143 )EQUIPMENT NUMBER: 012 & 043DWG. NO.:



1. Stop the Jeffery feeder by pushing the stop button on the panelboard.

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.





3. Electrical/480 volts

4.. None

5.. None



3. Cubical explosion

4. No hazard.

5. No hazard.

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

9

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: AMMONIA COOLER (400)EQUIPMENT NUMBER: 0042-41-400DWG. NO.: 42-F-0030/42-F-0031



** 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.



1. Ammonia/250 PSIG.


3. None

4. None

1. Health/Fire/Explosion.


3. No hazard.

4. No hazard.

REVIEWED BY:

AREA SAFETY COMMITTEE: YES

CHAIRMAN: JEFF GOLWITZER

DATE: 09/26/96

10

11

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: BFL AMMONIA VAPORIZER (403)EQUIPMENT NUMBER: 042-41-403DWG. NO.: 42-F-0031/42-F-0031



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 service.

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.

4. None

5. None

1. Health/Fire/Explosion. Thermal burns.


3. Thermal burns/Health.

4. No hazard.

5. No hazard.

REVIEWED BY:



DATE: 09/26/96

12

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: AIR CHILLER (404)EQUIPMENT NUMBER: 0042-41-1311DWG. NO.: 42-F-0050/42-F-0036



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.



2. Ammonia/150 PSIG. M. P. Steam


6. None

7. None


2. Health/Thermal burns. Personal injury.

3. Health/Personal injury.

6. No hazard.

7. No hazard.

REVIEWED BY:



DATE: 09/26/96

13

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: BAGHOUSE FAN ( 1311 )EQUIPMENT NUMBER: 1311DWG. NO.:



1. 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.

5. After work completion, inspect equipment and reverse procedures to put equipment back in service.



3. Fan rolling backward.

4. None

5. None



3. Personal injury.

4. No hazard.

5. No hazard.

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

14

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: BAGHOUSE SCREW CONVEYOR ( 2111 )EQUIPMENT NUMBER: 2111 DWG. NO.:



1. 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.





3. None

4. None



3. No hazard.

4. No hazard.

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

15

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: DRYER/COOLER EQUIPMENT SCRUBBER (117)EQUIPMENT NUMBER: 117 DWG. NO.: 42-F-0037



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.



3. Pond water/mildly acidic. 55 PSIG Steam. Phosphoric Acid (54%/30%) 180o + F. Sulfuric Acid (93%).



3. Eye/Skin irritation. Chemical/Thermal burns. Personal injury.

REVIEWED BY:



DATE: 09/26/96

16

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: DRYER/EQUIPMENT SCRUBBEREQUIPMENT NUMBER: 117 DWG. NO.: 42-F-0037




4. None

5. None

4. No hazard.

5. No hazard.

16

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: DRYER & COOLER CYCLONES ( 380 & 381 )EQUIPMENT NUMBER: 380 & 381DWG. NO.:



1. 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


REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

17

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1EQUIPMENT: DAP WATER COLLECTION TANK ( 154 )EQUIPMENT NUMBER: 154 DWG. NO.: 170B-123



1. 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.


4. After work completion, inspect the equipment and reverse procedures to put the equipment back in service.

1. None

2. O.T.W. under pressure.

3. None

4. None

1. No hazard.

2. Personal injury.

3. No hazard.

4. No hazard.

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

18

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: COOLER BAGHOUSE ( 306 )EQUIPMENT NUMBER: 306DWG. NO.:



1. 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

2. No Hazard

3. No hazard


2. No Hazard

3. No hazard

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

19

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: 54% ACID STORAGE TANK (502)EQUIPMENT NUMBER: 42-502 DWG. NO.: 42-F-0005



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.



3. Phosphoric acid 180o F.


1. Unexpected power surge/release of stored energy. Accidental start-up.


3. Chemical/thermal burns.


REVIEWED BY:


CHAIRMAN: JEF GOLWITZER

DATE: 09/26/96

20

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: 54% ACID STORAGE TANKEQUIPMENT NUMBER: 42-502DWG. NO.: 42-F-0005


5. Employees working on this equipment will place their personal lock(s) on the disconnect.


5. None

6. None

5. No hazard.

6. No hazard.

21

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: 54% ACID STORAGE TANK SPLITTER BOX (650)EQUIPMENT NUMBER: 42-650DWG. NO.: 42-F-0005



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. None

3. None


2. No hazard.

3. No hazard.

REVIEWED BY:



DATE: 09/26/96

22

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: AIR PRE-HEATER ( 403 )EQUIPMENT NUMBER: 403DWG. NO.:



1. 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.

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.



1. 150 lb steam and excess draft or air pressure.

2. Electrical / 480 volts

3. 150 lb. steam.

4. No Hazard

5. No Hazard

1. Physical injury from steam and air flow


3. Thermal burns

4. No hazard

5. No hazard

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

23

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP-1 EQUIPMENT: DEFOAMER TANK ( 511 )EQUIPMENT NUMBER: 511 DWG. NO.:



1. 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.

3. None

4. None

1. Eye irritation/Slippery liquid.

2. Eye irritation/Thermal burns/Slippery conditions.

3. No hazard.

4. No hazard.

REVIEWED BY:


CHAIRMAN:

JEFF A. GOLWITZER

DATE:

OCTOBER 1996

24

SPECIFIC LOCKOUT PROCEDURE PAGE 24PLANT: DAP 1 EQUIPMENT: AMMONIA COOLER (400)EQUIPMENT NUMBER: 0042-41-400DWG. NO.: 42-F-0030/42-F-0031



** 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. None

4. None



3. No hazard.

4. No hazard.

REVIEWED BY:



DATE: 09/26/96

25

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

26

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: BFL AMMONIA VAPORIZER (403)EQUIPMENT NUMBER: 042-41-403DWG. NO.: 42-F-0031/42-F-0031



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.


5. After work completion, inspect equipment and reverse the procedure to put the equipment back in service.

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.

4. None

5. None

1. Health/Fire/Explosion. Thermal burns.


3. Thermal burns/Health.

4. No hazard.

5. No hazard.

07/28/95 * 02/26/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

27

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: AIR CHILLER (1311)EQUIPMENT NUMBER: 0042-41-1311DWG. NO.: 42-F-0050/42-F-0036



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.



2. Ammonia/150 PSIG. M. P. Steam


6. None

7. None


2. Health/Thermal burns. Personal injury.

3. Health/Personal injury.

6. No hazard.

7. No hazard.

REVIEWED BY:



DATE: 09/26/96

28

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

29

SPECIFIC LOCKOUT PROCEDURE PAGE 29PLANT: DAP 1 EQUIPMENT: No.1 54% FEED PUMP (102A)EQUIPMENT NUMBER: 42-102ADWG. NO.: 42-F-0005



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. None

5. None




4. No hazard.

5. No hazard.

REVIEWED BY:



DATE: 09/26/96

30

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

31

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: No.2 54% FEED PUMP (102B)EQUIPMENT NUMBER: 42-102BDWG. NO.: 42-F-0005



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. None

5. None




4. No hazard.

5. No hazard.

REVIEWED BY:



DATE: 09/26/96

32

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

33

SPECIFIC LOCKOUT PROCEDUREPLANT: DAP 1 EQUIPMENT: BFL CONDENSATE PUMP EQUIPMENT NUMBER: DWG. NO.: 42-F-0031



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.





3. Ammoniated liquid.

4. None

5. None



3. Personal injury/Ammonia inhalation

4. No hazard.

5. No hazard.

07/24/95 * 10/11/96 * 10/17/96

REVIEWED BY:



DATE: 10/17/96

34

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: TAIL GAS SCRUBBER CIRCULATION PUMP (116/117)EQUIPMENT NUMBER: 116/117 DWG. NO.: 42-F-0038



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. None

5. None



3. Eye/skin irritation.

4. No hazard.

5. No hazard.

REVIEWED BY:



DATE: 09/26/96

35

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

36

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: "A" R/G PRE-SCRUBBER PUMP (119)EQUIPMENT NUMBER: 119DWG. NO.: 42-F-0031



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" Pre-scrubber 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.




3. Phosphoric acid/180° F.

4. None



3. Thermal and chemical burns.

4. No hazard.

REVIEWED BY:



DATE: 09/26/96

37

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: "A" R/G PRE-SCRUBBER PUMPEQUIPMENT NUMBER: 119DWG. NO.: 42-F-0031



5. None 5. No hazard.

06/09/95 * 02/26/96 * 08/19/96 * 09/26/96

38

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: "B" R/G PRE-SCRUBBER PUMP (120)EQUIPMENT NUMBER: 120DWG. NO.: 42-F-0031



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 Pre-scrubber 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. None




4. No hazard.

REVIEWED BY:



DATE: 09/26/96

39

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: "B" R/G PRE-SCRUBBER PUMPEQUIPMENT NUMBER: 120DWG. NO.: 42-F-0031




06/09/95 * 02/26/96 * 08/19/96 * 09/26/96

40

SPECIFIC LOCKOUT PROCEDUREPLANT: DAP 1 EQUIPMENT: "A" ACID SCRUBBER PUMP (120A)EQUIPMENT NUMBER: 120A DWG. NO.: 42-F-0037



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.


5. After work completion, inspect equipment and reverse the procedures to put the equipment back into service.




4. None

5. None




4. No hazard.

5. No hazard.

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

REVIEWED BY:



DATE: 09/26/96

41

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: "B" ACID SCRUBBER PUMP (120B)EQUIPMENT NUMBER: 120B DWG. NO.: 42-F-0037



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.





4. None

5. None




4. No hazard.

5. No hazard.

REVIEWED BY:



DATE: 09/26/96

42

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

43

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: DEFOAMER PUMP (233A)EQUIPMENT NUMBER: 0042-27-233ADWG. NO.: 44-F-0037



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.


5. After work completion, inspect equipment and reverse the procedures to put the equipment back in service.



3. Defoamer (oil) under pressure.

4. None

5. None



3. Personal injury.

4. No hazard.

5. No hazard.

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

REVIEWED BY:



DATE: 09/26/96

44

SPECIFIC LOCKOUT PROCEDUREPLANT: DAP 1 EQUIPMENT: "A" SLURRY PUMP (122A)EQUIPMENT NUMBER: 122ADWG. NO.: 42-F-0030



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 reverse procedures to put the equipment back in service.

1.Electrical/120 volts.

2.Electrical/480 volts.

3.Ammoniated slurry/235o F. Pond water/mildly acidic.

4.None

5.None

1.

2.

3.

4.

5.

06/08/95 * 02/26/96 * 08/19/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

45

SPECIFIC LOCKOUT PROCEDUREPLANT: DAP 1 EQUIPMENT: "B" REACTOR SLURRY PUMP (122B)EQUIPMENT NUMBER: 122BDWG. NO.: 44-F-0030



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 and4" Discharge valve with a Production Lock. Open and tag the 1" Drain valve. Close and tag the 3" Pond Water valve.





3. Ammoniated slurry/235° F. Pond water/mildly acidic.

4. None

5. None




4. None

5. No hazard.

06/08/95 * 02/26/96 * 08/19/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

46

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: "A" EFFLUENT RETURN PUMP (134A)EQUIPMENT NUMBER: 134A DWG. NO.: 42-F-0038



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.







4. None

5. None




4. No hazard.

5. No hazard.

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

REVIEWED BY:



DATE: 09/26/96

47

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: "B" EFFLUENT RETURN PUMP (134B)EQUIPMENT NUMBER: 134B DWG. NO.: 42-F-0038



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.







4. None

5. None




4. No hazard.

5. No hazard.

REVIEWED BY:



DATE: 09/26/96

48

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

49

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: CYCLONIC SCRUBBER PUMP(120)EQUIPMENT NUMBER: 0042-50-120DWG. NO.: 42-F-0038



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.




3. Process Water.

4. None

5. None



3. No hazard.

4. No hazard.

5. No hazard.

07/26/95 * 02/26/96 * 08/19/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

50

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: ONCE THRU WATER PUMP (154)EQUIPMENT NUMBER: 154 DWG. NO.: 170B-123



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.





3. Once thru water.

4. None

5. None



3. Personal injury.

4. No hazard.

5. No hazard

12/06/95 * 09/26/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/97

51

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: HYDRAULIC SYSTEM PUMPS (640E-W)EQUIPMENT NUMBER: 42-640E-WDWG. NO.:



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.




3. Hydraulic Fluid 750 PSIG.

4. None



3. Personal injury/Health.

4. None

REVIEWED BY:



DATE: 09/26/96

52

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: HYDRAULIC SYSTEM PUMPSEQUIPMENT NUMBER: 42-640E-WDWG. NO.:




07/26/95 * 09/26/96 * 09/26/96

53

SPECIFIC LOCKOUT PROCEDURE PAGE 53PLANT: DAP 1 EQUIPMENT: INTREMEDIATE CONVEYOR (016)EQUIPMENT NUMBER: 42-016 DWG. NO.: 50-F-0002



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.



1. Granulated material flow.



4. None

5. None

1. Personal injury.



4. No hazard.

5. No hazard.

REVIEWED BY:



DATE: 09/26/96

54

06/14/96 * 09/26/96 * 09/26/96

55

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: "A" & "B" DEDUSTING SCREEN EQUIPMENT NUMBER: DWG. NO.: 42-0039



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. None

4. None



3.

4. No hazard.

07/26/95 * 01/29/96 * 08/19/96

REVIEWED BY:


CHAIRMAN: JEFF GOLSITZER

DATE: 09/26/96

56

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: RECYCLE ELEVATOR (102)EQUIPMENT NUMBER: 102 DWG. NO.: 42-F-0035



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.









REVIEWED BY:

AREA SAFETY COMMITTEE

CHAIRMAN:

DATE:

57

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: RECYCLE ELEVATOR (102)EQUIPMENT NUMBER: 102DWG. NO.: 42-F-0035




5. None

6. None

5. No hazard.

6. No hazard.

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

58

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: GRANULATOR (103)EQUIPMENT NUMBER: 0042-55-103DWG. NO.: 42-F-0034/30/31/35



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).





5. Ammonia liquid and vapors. Medium Pressure Steam 150 PSIG.





5. Health-Thermal burns.

REVIEWED BY:



DATE: 09/26/96

59

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: GRANULATOR (103)EQUIPMENT NUMBER: 0042-55-103 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.



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.

60

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: LUMPBREAKER (105)EQUIPMENT NUMBER: 105 DWG. NO.: 42-F-0032



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.




3. None

4. None



3. No hazard.

4. No hazard.

06/22/95 * 02/26/96 * 08/19/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

61

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: SCREENS FEED ELEVATOR (106)EQUIPMENT NUMBER: 106DWG. NO.: 42-F-0032



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.









REVIEWED BY:



DATE: 09/26/96

62

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: SCREENS FEED ELEVATOREQUIPMENT NUMBER: (106)DWG. NO.: 42-F-0032



6. After work completion, inspect equipment and reverse procedures to put the equipment back into service.

5. None

6. None

5. No hazard.

6. No hazard.

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

63

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: PROCESS SCREENS (107A-D) EQUIPMENT NUMBER: 107A-DDWG. NO.: 42-F-0035



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.


1. Granulated Material Flow.



4. None

5. None

1. Personal injury.



4. No hazard.

5. No hazard.

06/22/95 * 02/26/97 * 08/19/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

64

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: CAGE MILLS INNER AND OUTER CAGE (108A-D)EQUIPMENT NUMBER: 4305-06-108A-D DWG. NO.: 42-F-0035



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.




3. None

4. 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

REVIEWED BY:



DATE: 09/26/96

65

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: DRAG FLIGHT CONVEYOR (110)EQUIPMENT NUMBER: 4305-06-110DWG. NO.: 42-F-0035



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.





1. Accidental Start-up.


3. Accidental Start-up.


REVIEWED BY:



DATE: 09/26/96

66

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: DRAG FLIGHT CONVEYOREQUIPMENT NUMBER: 4305-06-110DWG. NO.: 42-F-0035



6. After work completion,inspect equipment and reverse procedures to put the equipment back in service.

5. None

6. None

5. No hazard.

6. No hazard

06/26/95 * 02/26/96 * 09/26/96

67

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: PRODUCT COOLER (111)EQUIPMENT NUMBER: 111DWG. NO.: 42-F-0036



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. None

4. None



3. No hazard.

4. No hazard.

07/18/95 * 01/29/96 * 08/19/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

68

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: PRODUCT ELEVATOR (113)EQUIPMENT NUMBER: 113DWG. NO.: 42-F-0036



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.


4. After work completion, inspect equipment and reverse procedure to put the equipment back in service.



3. None

4. None



3. No hazard.

4. No hazard

07/26/95 * 01/29/96 * 08/19/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

69

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: PRODUCT CONVEYOR (141)EQUIPMENT NUMBER: 141DWG. NO.: 42-F-0036



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. None

4. None



3. No hazard.

4. No hazard.

07/26/95 * 01/29/96 * 08/19/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

70

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: FINES CONVEYOR (146)EQUIPMENT NUMBER: 146 DWG. NO.: 170D-140



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. Active equipment traffic area.

4. None



3. Payloaders.

4. No hazard.

12/05/95 * 01/29/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

71

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: NORTH DAP DISTRIBUTION CONVEYOR (415)EQUIPMENT NUMBER: 415DWG. NO.: 170D-40



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. None

4. None



3. No hazard.

4. No hazard.

12/04/95 * 01/29/96 * 08/19/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

72

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: DAP DISTRIBUTION CONVEYOR AND TRIPPER (417/417A)EQUIPMENT NUMBER: 42-417/417A DWG. NO.: 50-F-0002



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.



1. Granulated material flow.



4. None

5. None

1. Personal injury.



4. No hazard.

5. No hazard.

REVIEWED BY:



DATE: 09/26/96

73

06/14/96 * 09/26/96 * 09/26/96

74

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: PRE-SCREEN RECYCLE CONVEYOR EQUIPMENT NUMBER: DWG. NO.: 170D-140



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. None

4. None



3. No hazard.

4. No hazard.

12/05/95 * 09/26/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

75

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: ROTARY DRYER (104)EQUIPMENT NUMBER: 104DWG. NO.: 42-F-0032



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.





4. None

5. None




4. No hazard.

5. No hazard.

07/20/95 * 09/26/96 * 10/17/96

REVIEWED BY:



DATE: 10/17/96

76

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: COMBUSTION CHAMBER (104-1)EQUIPMENT NUMBER: 104-1DWG. NO.: 42-F-0032



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.



3. Natural Gas/No.6 Fuel Oil/140o + F. Insufficient oxygen supply.

4. Steam/150 PSIG. Plant air 30 PSIG.



3. Thermal Burns/Fire or explosion. Health.

4. Thermal burns/Personal injury.

REVIEWED BY:


CHAIRMAN:

DATE:

77

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: COMBUSTION CHAMBEREQUIPMENT NUMBER: 104-1 DWG. NO.: 42-F-0032



6. After work completion,inspect equipment and reverse procedures to put the equipment back in service.

5. None

6. None

5. No hazard.

6. No hazard

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

78

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: I.D.FAN (116)EQUIPMENT NUMBER: 116DWG. NO.: 42-F-0038



1. Stop the I.D.Fan Motor (116) by pushing the stop button on the panel board.

2. Open and lock the disconnect for the I.D. Fan Motor (116) 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.




3. Fan rolling backward.

4. None

5. None



3. Personal injury.

4. No hazard.

5. No hazard.

07/20/95 * 08/19/96 * 09/26/96 * 10/17/96

REVIEWED BY:



DATE: 10/17/96

79

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: DRYER/COOLER EQUIPMENT SCRUBBER (117)EQUIPMENT NUMBER: 117 DWG. NO.: 42-F-0037



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.



3. Pond water/mildly acidic. 55 PSIG Steam. Phosphoric Acid (54%/30%) 180o + F. Sulfuric Acid (93%).



3. Eye/Skin irritation. Chemical/Thermal burns. Personal injury.

REVIEWED BY:



DATE: 09/26/96

80

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: DRYER/EQUIPMENT SCRUBBEREQUIPMENT NUMBER: 117 DWG. NO.: 42-F-0037




4. None

5. None

4. No hazard.

5. No hazard.

07/17/95 * 01/29/96 * 09/26/96

81

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: T.G.SCRUBBER (148)EQUIPMENT NUMBER: 0042-50-148DWG. NO.: 42-F-0038



1. Stop I.D.FAN (116), and the North and South Tailgas Scrubber Recirculation Pumps (116N & 117S), by pushing the stop buttons on the panel board.

2. Open and lock the disconnects for the I.D.Fan (116) and the North and South Recirculation Pumps (116N & 117S) in the Motor Control Center (MCC) with a Production Lock.

3. Close and chain lock 10" Pond Water valve and 6" valve with a Production Lock. Open and tag 3" drain valve and 1/2" drain valve.


5. After work completion, inspect equipment and reverse the procedures to put the equipment back into service.



3. Pond Water/mildly acidic

4. None

5. None




4. No hazard.

5. No hazard.

REVIEWED BY:



DATE: 09/26/96

82

06/26/95 08/19/96 * 09/26/96

83

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: BURNER BLOWER (153)EQUIPMENT NUMBER: 153 DWG. NO.: 42-F-0025



1. Stop the Burner Blower (153) by pushing the stop button on the panel board.

2. Open and lock the disconnect for the Burner Blower (153) in the Motor Control Center (MCC) with a Production Lock.





3. None.

4. None.



3. No hazard.

4. No hazard.

07/17/95 * 01/29/96 * 09/26/96

REVIEWED BY:



DATE: 06/26/96

84

SPECIFIC LOCKOUT PROCEDUREPLANT: DAP 1 EQUIPMENT: CYCLONIC SCRUBBER (310)EQUIPMENT NUMBER: 0042-50-310DWG. NO.: 42-F-0038



** If Cyclonic Scrubber entry is required, the Plant must be down. **

1. Stop the Cyclonic Recycle Pump (120) and the I.D.Fan (116) by pushing the stop button on the panel board.

2. Open and lock the disconnect for the Cyclonic Recycle Pump (120) and the I.D.Fan (116) in the Motor Control Center (MCC) with a production lock.

3. Close and chain lock the 2" Once Thru Water Valve with a Production Lock.

4. Employees required to work on this equipment will place their personal lock(s) on the equipment designated.



3. Pressurized once thru water.

4. None



3. Personal injury.

4. No hazard.

REVIEWED BY:



DATE: 09/26/96

85

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: CYCLONIC SCRUBBEREQUIPMENT NUMBER: 4250-310DWG. NO.: 42-F-0038




06/12/95 * 08/19/96 * 09/26/96

86

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: R/G PRE-SCRUBBER EQUIPMENT NUMBER: 0042-50-383DWG. NO.: 42-F-0031/42-F-0037



1. Stop R/G Pre-scrubber pumps (119A & 120B) by pushing the stop button on the panel board.

2. Open and lock the disconnects for the R/G Pre-scrubber pumps (119A & 120B) in the Motor Control Center (MCC) with a Production Lock.

3. Close and chain lock the 12" Suction valves and the 10" discharge valves with a Production Lock. Open and tag the 2" drain valves.

4. Close and chain lock the 1" H2SO4 valve, the 1" Medium Pressure Steam valve, and 3" 22% valve. Open and tag the R/G Pre-scrubber 2" Drain valve.

5. Close and tag 2" Process Water line valve.




3. Phosphoric acid 180o F./Pond water mildly acidic.

4. Phosphoric acid 180o F./Pond water mildly acidic/Medium Pressure Steam/ Ammoniated Fumes.

5. Water under pressure.

6. None



3. Chemical burns. Eye/skin irritation.

4. Chemical/thermal burns. Eye/skin irritation. Health

5. Personal injury.

6. No hazard.

REVIEWED BY:


CHAIRMAN:

DATE:

87

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: R/G PRE-SCRUBBER EQUIPMENT NUMBER: 0042-50-383 DWG. NO.: 42-F-0031/42-F-0037




J:\WPC\DAP1\383 07/25/95

88

SPECIFIC LOCKOUT PROCEDUREPLANT: DAP 1 EQUIPMENT: BAGHOUSE AIR COMPRESSOR (1313-1-2)EQUIPMENT NUMBER: 4248-1313-1-2DWG. NO.:



1. Stop the Baghouse Air Compressor(s) by (1313-1-2) pushing the stop button in the field.

2. Open and lock the disconnect for the Baghouse Air Compressor(s) (1313-1-2) in the Motor Control Center (MCC) with a Production Lock.

3. Bleed down Baghouse Air Compressor(s) (1313-1-2) and Receiver.





3. Compressed air.

4. None

5. None



3. Personal injury.

4. No hazard.

5. No hazard.

06/20/95 * 09/26/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

89

SPECIFIC LOCKOUT PROCEDURE PAGE 89PLANT: DAP 1 EQUIPMENT: 54% ACID STORAGE TANK AGITATOR (034)EQUIPMENT NUMBER: 42-034DWG. NO.: 42-0005



1. Stop the 54% Storage Tank Agitator (034) by pushing the stop button on the panel board.

2. Open and lock the disconnect for the 54% Acid Storage Agitator (034) in the Motor Control Center (MCC) with a Production Lock.





3. None

4. None



3. No hazard.

4. No hazard.

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

REVIEWED BY:



DATE: 09/26/96

90

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: REACTOR (501)EQUIPMENT NUMBER: 0042-02-501DWG. NO.: 42-F-0030/31/37



1. Stop the 54% Acid feed pumps (102 A & B), the R/G Pre-scrubber Pumps (119A & 120B), and the Acid Scrubber Pumps (Venturi) (120A & 120B) by pushing the stop button on the panel board.

2. Open and lock the disconnect(s) for the 54% Acid feed pumps (102 A & B), the R/G Pre-scrubber Pumps (119A & 120B) and the Acid Scrubber Pumps (Venturi) (120A & 120B) in the Motor Control Center (MCC) with a Production Lock.

3. Close and chain lock the 4" valve located behind the Granulator, with a Production Lock. Steam purge the Ammonia Supply Line and Ammonia Vaporizer. Close and chain lock 3" valve at Ammonia Vaporizer discharge. Close and chain lock 8" valves from BFL Vaporizer with a Production Lock. Open and tag 3/4" vent valve.



3. Ammonia liquid/vapors/250 PSIG.




REVIEWED BY:



DATE: 09/26/96

91

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: REACTOREQUIPMENT NUMBER: 0042-02-501DWG. NO.: 42-F-0030/31/37


4. Close and chain lock 4" valve at R/G Pre-scrubber Pumps (119A & 120B), and 8" valve from Acid Scrubber Pumps (Venturi) (120A & 120B) with a Production Lock.

5. Disconnect 2" AAN Supply line at AAN truck. Close and chain lock 2" valve at Reactor with a Production Lock. Open and tag 1" drain line. Close and chain lock the 2" H2S04 valve with a Production lock.

6. Close and chain lock 4" 30% Regular Jumper line valve and 4" AP line valves. Close and chain lock 4" valve on Jumper line from AP line to Regular 54% Acid line. Close and chain lock 4" valve, also located on the regular 54% line. All valves are to be locked with a Production Lock.

4. Phosphoric Acid/180o F.

5. Ammonium Nitrate.

6. Phosphoric Acid/180o F./Pond water mildly acidic.



5. Chemical burns.

6. Chemical burns.

7. Chemical/thermal burns/Eye/skin irritation.

92

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: REACTOREQUIPMENT NUMBER: 0042-02-501 DWG. NO.: 42-F-0030/31/37


7. Close and chain lock 1" Med. Press. Steam valves with a Production Lock.

8. Open and tag the 6" Reactor Drain valve.





9. None

10. None


8. Chemical/Thermal burns.

9. No hazard.

10. No hazard.

06/15/95 * 09/26/96 * 09/26/96

93

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: 54% ACID STORAGE TANK (502)EQUIPMENT NUMBER: 42-502 DWG. NO.: 42-F-0005



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.









REVIEWED BY:


CHAIRMAN: JEF GOLWITZER

DATE: 09/26/96

94

SPECIFIC LOCKOUT PROCEDURE

PLANT: DAP 1 EQUIPMENT: 54% ACID STORAGE TANKEQUIPMENT NUMBER: 42-502DWG. NO.: 42-F-0005




5. None

6. None

5. No hazard.

6. No hazard.

06/21/95 * 02/26/96 * 09/26/96

95

SPECIFIC LOCKOUT PROCEDURE PLANT: DAP 1 EQUIPMENT: 54% ACID STORAGE TANK SPLITTER BOX (650)EQUIPMENT NUMBER: 42-650DWG. NO.: 42-F-0005



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. None

3. None


2. No hazard.

3. No hazard.

06/21/95 * 02/26/96 * 09/26/96

REVIEWED BY:



DATE: 09/26/96

96

Documents

TABLE OF CONTENTS - The Mosaic Company the Dryer Spillage Conveyor (005) by pushing the stop button on the panel board. 2. Open and lock the disconnects for the Dryer