HAZARD ANAYLSIS SAFETY ACTION PLAN

DOW CHEMICAL
Institute, WV

Revision 3
Original Date Issued: August 4, 2016
 Hazard Analysis Safety Action Plan (HASAP)

Dow Chemical Institute, WV

TABLE OF CONTENTS

1.0 GENERAL SITE INFORMATION

2.0 SITE AND PROJECT DESCRIPTION

3.0 PROJECT SCOPE AND SCHEDULE

4.0 HSE REQUIREMENTS

5.0 KEY PROJECT CONTACTS

6.0 SITE ACCESS REQUIREMENTS AND TRAINING

7.0 HSE PROGRAM

8.0 RISK IDENTIFICATION AND ASSESSMENT

9.0 INJURY MANAGEMENT

10.0 GENERAL EMERGENCY RESPONSE

11.0 ATTACHMENTS

12.0 DOCUMENT CHANGE HISTORY

13 HASAP REVIEW AND APPROVAL

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1.0 GENERAL SITE INFORMATION

Client Name/Site Dow
Street Address Route 25 Institute, WV 25112
Plant Entrance Contractor East Gate
Dow Emergency Phone Number (from a plant phone) Ext. 5555
Dow Emergency Phone Number (from a non-plant phone) (304) 747-5555
Dow Security Phone Number (304) 747-4562
Dow Security Non-Emergency Phone Number (304) 747-4444
Dow Welcome Center Phone Number (304) 747-7718

2.0 SITE AND PROJECT DESCRIPTION

The Jacobs WV/KY Operations has been contracted to provide professional services to execute capital projects
and other work as directed by Dow Chemical.
3.0 PROJECT SCOPE AND SCHEDULE
3.1 Description of Work
The general work description for the Jacobs employees is as follows:
Inspection and assessments
Engineering support during shutdowns
Our work requires the Jacobs employees to travel throughout all areas of the plant, including process units.
3.2 Work Schedule
The work schedule varies depending on workload and client requests. No overtime work is scheduled at this
time.
3.3 Project Manpower Construction Support
The Jacobs project resource level for personnel varies depending on workload.
4.0 HSE REQUIREMENTS
4.1 Dow Chemical and Jacobs Requirements
Specific HSE policies and procedures are identified in the following documents and/or through the following
regulatory agencies.
Dow Chemicals Environment, Health and Safety (EH&S) Policies and Procedures
Jacobs Health, Safety and Environment (HSE) Policies and Procedures
Federal OSHA 1910 and 1926 standards
Environmental Protection Agency
State and Local requirements
4.2 HSE Roles and Responsibilities
Personnel at all levels have the responsibility to actively participate in the HSE process and stop, or bring to the
attention of management, any at risk behavior, unsafe condition and/or potentially harmful environmental
practice.
Additionally, specific HSE roles and responsibilities are provided below.
Immediately correct any imminent danger situations such as exposure to falls from elevations, electrical shock
hazards, exposure to improperly protected excavations, LOTO violations, etc.
Notify supervision if you have an insufficient understanding of the task to be performed, of HSE procedures
and of assigned safety equipment.
Promptly report incidents involving personnel, equipment, property or the environment, no matter how minor.
Learn the approved HSE safe practices that apply to your work and practice them at all times.
Ask for assistance from the HSE Department or client contact when unsure of a work or safety practice.

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Promptly report safety device malfunctions and tag the device to warn others of the hazard.
Never attempt to do a job alone when good judgment indicates assistance is needed.
Inspect, use and maintain personal protective equipment that has been provided.
Observe safe practices off the job as well as on the job.
5.0 KEY PROJECT CONTACTS
5.1 Jacobs Project Management
Name Title Email Phone
Ron Rushworth Project Manager ron.rushworth@jacobs.com 304-720-4119 (office)
304-382-7768 (cell)
Lynn Roncco HSE Manager lynn.roncco@jacobs.com 317-313-4851 (cell)
317-423-4851 (office)
5.3 Key Dow Chemical Contacts
Name Title Email Phone
Jon Putnam Responsible Care Leader jputnam@dow.com 304-747-1165 (O)
Mary Byrd Security byrdml@dow.com 304-747-4562 (O)
Andy Altman Project Manager altmanam@dow.com 304-747-1958 (O)
6.0 SITE ACCESS REQUIREMENTS AND TRAINING
6.1 Site Access
Entry into the facility is controlled by Dow Chemicals Security. The Dow Institute Plant has established specific
requirements for gaining access to the plant. These include a drug screen, background check, verification of
citizenship and legal authorization to work. Verification and validation of the employees Social Security Number
is also required.
See Attachment A for the Dow Institute documentation (the documents are currently under revision by Dow
Security and they may change without notice).
6.2 Drug Screens
All Jacobs employees are subject to the provisions of the Dow Institute, US Methanol and Jacobs Drug Screening
Policy. Drug screens are coordinated through Jacobs HR. The test must be conducted in advance of your site
visit. Additional screening may include random, post-incident and/or for cause testing.
6.3 Background Check
A background check is required for entry into the facility. Background checks may take up to 7 days or more to
complete, so adequate lead time is required. Jacobs HR will coordinate background checks.
6.4 Safety Training
Completion of Basic Plus training is required for unescorted entry into the Dow Institute site. The training is
delivered at the Regulatory Training Center (RTC) on 120 3rd Avenue in South Charleston, WV.
For first time entrants into the Dow Institute site, the 5-hour Basic Plus, instructor-led training course is offered on
Monday and Wednesday at 8:00 AM.
For Jacobs WV/KY engineers, three additional classes are required. The classes are computer-based and each
class is approximately 45 minutes in length.
Annual Basic Plus refresher training is one hour in length and offered Monday through Friday from 7:00 AM
3:30 PM.
All training at the RTC must be scheduled at least 48 hours in advance. Contact Christel Mize at 304-720-8524 or
by email to schedule this training. If you do not have the required training, you must be escorted by a Dow
representative at all times while at the site.
Additional training may be required depending on your job tasks and the hazards associated with your work.
6.5 Badging
Upon completion of the safety training, an ID card will be issued from the RTC. This card, along with the
completed verification form, is presented to the receptionist at the Dow Institute Welcome Center. A Dow Institute
Site badge will be issued and your Dow Host will be contacted to escort you to your work location on the first visit.
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Your badge must be visible at all times while working at the Dow Institute Site.
6.6 TWIC Card Requirements
The area that requires TWIC card access will include the entire fenced entire area to the south of the railroad
tracks (Barge unloading area). Prior access to the gates will be removed and will only be reactivated when the
individual requesting access to this area brings a valid TWIC card to the reception center in Bldg. 8403 for
validation.
Individuals who require access to this area and are not valid TWIC Card holders will be required to follow the
WVO escort process. This process will be managed via the main Gate.
7.0 HSE PROGRAM
7.1 HSE Program Implementation
Core HSE program elements shall be as follows:
Safe Plan of Action (SPA)
When driving to the site, a driving SPA will be completed.
All tasks conducted in the field require the development of a SPA at the location where the task is being
performed.
Safety Observation Reports (SOR)
Jacobs employees are encouraged to participate in the Jacobs SOR process and/or the clients
equivalent process. Observations related to the clients site should be brought to the attention of your
client representative.
Employees are also encouraged to utilize the Jacobs SOR App that is available through JacobsConnect.
Cell phones are not allowed in some areas of the facility, but the SOR can be entered into the App at a
safe location.
7.2 Work Control
A Safe Work Permit is required for all hands on work within the process operating areas. The need for safe
work permits will be determined by the unit operators and will depend on the scope of work.
Safe Work Permits can be issued for up to 12 hours, but it will be terminated once you leave the unit or
discontinue work. Once the task is completed, return the permit to the operator that issued the permit for
termination.
Unit sign-in does not replace the requirement for a Safe Work Permit.
7.3 Hazard Communication
Safety Data Sheets (SDSs) are maintained and available through Dow Chemicals electronic database.
Area-specific HAZCOM training is required for entry into each operating unit. It is preferred that arrangements are
made in advance before your visit to the unit. The training is conducted at the respective unit control room and it
is valid for one year.
7.4 Project PPE and Clothing Requirements
The following are PPE and clothing requirements.
Hardhats (ANSI Z89.1)
Hardhats will be worn with the bill forward to protect the face and eyes from dropped objects or debris.
Eye and Face Protection (ANSI Z87.1)
Safety glasses with rigid side shields are a requirement. This includes both prescription and non-prescription
eyewear.
Clear safety glasses will be worn inside all buildings.
Mono goggles are required where posted and must be carried at all times.
Foot Protection (ANSI Z41 or ASTM F2412-05 & F2413-05)
Safety toe footwear made of non-porous leather or synthetic material that at a minimum, covers the ankle, is
required.

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Hearing Protection
Hearing protection is required in all posted areas.
Hearing protection should also be worn in all areas where noise levels are such that one must raise their
voice to be heard when standing next to another employee.
Hand Protection
All employees are required to wear protective gloves, which are appropriate for the task, when out in the field
or inside a process unit.
Clothing and Attire
FRC (flame retardant clothing) is required in all production and process units, including electrical handling
facilities, loading racks/material handling facilities, etc.
7.5 Work at Elevation
OSHAs General Industry standard for fall protection requires the use of personal fall arrest equipment when not
protected by a standard guardrail system or approved work platform and when there is an opportunity to fall four
(4) feet or more from one level to another. Continuous or 100% tie-off is required at all times and the use of
double, self-retractable lanyards or a retractable lifeline is required for this work.
Tie-off requirements in construction areas may vary and it is recommended that you check with your Dow Host to
identify what the tie-off requirements will be. OSHAs Construction Standard allows for tie-off at six (6) feet or
higher, but Dow may have a plant-wide standard that is more stringent than six feet.
Tie-off is also required in all aerial lifts.
Prior to accessing roofs, a roof assessment will be completed to identify fall hazards and other hazards such as
exposure to hazardous materials that may be released through vents or relief valves.
Fall protection training is required on an annual basis and it must be current before work at elevation is permitted.
The Jacobs Elevated Work SPA must be completed prior to working at elevation.
7.6 Cell Phone and Camera Use
All process unit areas are Class I/Division II classified areas and all electronic equipment used in the process
areas must be certified as intrinsically safe. The use of cell phones is not allowed.
The use of a camera, including the cell phone camera, is strictly forbidden on Dow Chemical property. If pictures
must be taken, your Dow Chemical host will give you a camera use authorization form. The Dow WV
Responsible Care Leader must approve all camera requests. The approval is good for one calendar year and it
must be renewed by January 1 of each year.
All photographs must be approved and released by a Dow Chemical representative before leaving the site.
7.7 Smoking
Smoking is prohibited on the property.
7.8 Fatigue Management
Dow Chemical and Jacobs have established work guidelines when assessing worker fatigue risk and have
identified the appropriate control measures to minimize fatigue for employees.
Fatigue may be the result of working long hours per day, working for extended periods, working call outs and
holdovers, performing physically or mentally demanding tasks, working in extreme environmental conditions or
performing work with exposures to other factors which place employees at higher risk for fatigue.
Approval of work beyond the limits described below will only be considered when stopping work is likely to result
in an EH&S related incident or non-compliance with government requirements.
If deviations to these guidelines are known, in advance of the start of work, a written justification and risk
assessment is required with approval from Jacobs Management.
Employees may not work:
More than 16 consecutive hours and must have at least 8 hours off before and after working 16 consecutive
hours. On-site meetings count toward the 16-hour maximum.
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More than 13 consecutive days without at least 24 hours off prior to returning to work. Consecutive days are
based on actual days worked. Four hours of actual work will constitute a work day for tracking consecutive
days worked.
More than 84 hours in a week. Week is defined as 7 consecutive calendar days.
8.0 RISK IDENTIFICATION AND ASSESSMENT
A risk assessment has been documented as part of this HASAP. See Attachment B.
The risk assessment is a living document and it should be periodically reviewed and updated to ensure it is
maintained current with the scope of the project and the hazards that exist on the site. Revisions to the risk
assessment resulting in changes to hazards and/or controls will be communicated to the project team as
appropriate.
9.0 INJURY MANAGEMENT
9.1 Non-Life Threatening Medical Emergencies
Ensure notifications have been made to Jacobs and Dow and transport the employee to the designated Jacobs
healthcare provider.
The following healthcare providers have been identified.
MedExpress Urgent Care Cross Lanes or Dr. Syam B. Stoll
5161 Washington Street West 1563 Sand Plant Road
Cross Lanes, WV 25313 South Charleston, WV 25309
304-755-5323 304-756-1550

9.1 Life Threatening Medical Emergencies

Dow will provide immediate medical care and attention in the event of a serious or life threatening medical
emergency. Care will be limited to stabilization of the injured employee until EMS arrives and transports the
employee to the hospital.
10.0 GENERAL EMERGENCY RESPONSE
10.1 General Response
Dow has an extensive emergency response and alarm system. The alarms may sound for a fire or explosion,
toxic gas release or weather alert.
In the event the emergency alarm sounds, all work must stop and employees are to report back to the control
room from where they signed in, unless the area is no longer safe. If you cant safety reach the control room, call
the Emergency Phone Number and explain your circumstance. Site security will assist you in finding an
acceptable shelter and they will record your location for head count purposes.
The plant is equipped with an emergency alarm pull box system. If at any time you witness or experience an
emergency (injury, illness, fire, spill, release), locate and pull the nearest emergency alarm box. The Dow
Emergency response Team is equipped to handle all emergency situations.
If the emergency alarm system is activated, an alarm will sound, alerting personal of an emergency. The alarm
sound will be followed by an automated voice that will report the exact location of the alarm. If you pull an
emergency alarm, remain at the alarm box until emergency responders arrive. If it is not safe to remain in the
area, leave and call the Emergency Phone Number to relay information to emergency responders.
11.0 ATTACHMENTS

Attachment A Dow Chemicals Site Access Documentation

Dow Institute Plant

Access Documentation.pdf

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Attachment B Dow Chemical Risk Assessment
Dow Institute
Engineering Risk Assessment.pdf
12.0 DOCUMENT CHANGE HISTORY
Rev. No. Changed By
1 Lynn Roncco
2 Lynn Roncco
3 Lynn Roncco
Hazard Analysis Safety Action Plan (HASAP)
Dow Chemical Institute, WV
Document Change History
Date Brief Description of Change
11/17/16 See paragraph 6.6 for TWIC card requirements
2/15/17 See paragraph 7.5 for new General Industry fall protection
requirements at 4 feet or higher. NOTE: Dual, self-retracting
lanyards are required for this work. Six foot lanyards are not
to be used.
4/1/17 See paragraph 7.1 for SOR requirements and reference to
the new Jacobs phone App.
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13.0 HASAP REVIEW AND APPROVAL

Lynn Roncco August 8, 2016

HSE Manager Signature Date
317-313-7392

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