Presentation on theme: "Specific Safety Procedures"— Presentation transcript:
1 Specific Safety Procedures Wisconsin Rapids Mill of NewPageWelcome to NewPage CorporationThe following presentation is an overview of specific information necessary for your personal safety as well as to insure you have the proper information relative to safety rules, procedures and environmental requirements while working at any of the Central WI Mills of NewPage. This orientation is intended to qualify you to work as a contractor at the Wisconsin Rapids, Biron, and Stevens Point Mills of NewPage Corporation.(Video of Michelle at table talking w/safety posters in background)At NewPage, we are committed to conducting our business in a responsible manner, providing a safe and healthy workplace and minimizing our impact on the environment. A part of our commitment to our employees and contractors, we have made safety our number one core value. Our mission is to operate our facilities in a manner so that no one gets hurt. Our goal is to reach zero injuries. This commitment is the foundation for the NewPage Safety Process.Once you receive and understand the content of this orientation and provide documentation, you can begin work at any of the Central WI Mills for one year. This qualification period runs from June 1, to June 1, each year. We allow this training for qualification to be in advance of June 1st for the following year by 40 days but the expiration date is a strict June 1, deadline.As a Contractor, safety is achieved by your efforts to follow proper procedures, utilize protective equipment, and to encourage safe behavior in all that you do. This effort will ensure the protection of people, equipment, and the environment.
2 Electrical Safety Training Wisconsin Rapids MillThis section of today’s class is on Electrical Safety which includes the dangers of contact with electrical energy as well as arc flash.Electrical Safety Training
3 Summary of WR Mill Electrical Safety Policy ALL Contractor Employees are responsible for:Having an awareness of the electrical hazards in their workplaces. (cords, overhead lines, buried cables, disconnected cables)Reporting electrical occurrences and all recognizable hazards by work order and to their supervisor.Reporting electrical shocks as injuries to their supervisors.Reading, understanding, and following all applicable procedures having electrical requirements.Adopting safe electrical work practices.Attending appropriate electrical safety awareness training and other training as requiredUsing appropriate personal protective equipmentREAD
4 Electrical Fault Through Air What is Arc Flash?Electrical Fault Through AirTemperatures can reach 35,000 °F (Oxyacetylene ≈ 6000 °F)Copper instantly vaporizes- Expands 67,000 times from solid to gas- Mechanical forces similar to dynamiteMolten Metal and Shrapnel ReleasedPressure WaveIntense Light (Similar to Welding)Loud Sound (> 140 dB)An Electric Arc Furnace is essentially a controlled arc flashSerious Burn injuries can occur as an indirect result of a faulted electrical circuit. An Arc flash occurs when dangerous levels of energy are released at the point of an electrical arc.A typical cause of an arc flash would be contacting a live energized circuit with a conductive material. The electrical energy is released through the air as the current establishes an electrical path to ground through the conductive material.The arc flash occurs in a time frame of ¼ cycle or 1/240th of a second. Temperatures associated with an arc flash can reach 35,000F.The copper that is vaporized expands 65,000 times as it goes from solid to gas, which creates a massive pressure waveThis is why we require long-sleeve, non-melting clothes in MCC rooms, even for hanging locks.Arc flash events don’t occur frequently, but they occur somewhere in the US on an average of once per day, sending victims to burn centers
5 Summary of WR Mill Electrical Safety Policy Category 0 apparel will be required to enter an MCC Room at all times for all personnelCategory 0 apparel consists of:100% non-melting clothes (cotton, wool)Cotton UnderclothesLong Pants, Long SleevesAll personnel who operate electrical equipment are required to wear natural fiber long sleeved shirts and pants or available arc rated clothing and leather gloves. This will put personnel at a level 0 hazard risk category.Includes Local Disconnects for slitters, Welding Outlets, Lighting Panel breakersAny plasticized designs on clothing limited to 4” x 4”Burns > 30% of body reduce survival chancesIncludes clothing worn under Arc Rated clothes55
6 Examples of non-melting shirts with designs NOT OKOK(Under long sleeves)OKShirts that have meltable plastic labels shall not be worn under under an additional long sleeve natural fiber shirt to operate electrical equipment UNLESS the label is less than 16 sq inches (4x4 inches).The Green Bay Packer and Wisconsin Badger shirts has a logo that is less than 16 sq inches (4x4 inches), so it would be OK to wear under a long-sleeve shirt.The others are more than 16 square inches, so it would not be appropriate to wear under a NON-MELTING long-sleeve shirt for operating equipment.We are not the TSA and will not be setting up full body scans to see that everyone is in compliance. Like all other PPE, YOU need to make the decision to wear proper equipment for your safety.Ink Screen Printed shirts are OK (like Miron or VanErt) if you can still see through the fabric.
7 WR Mill Electrical Safety - Key Items Many MCC rooms have green welders jackets either located outside the room, or immediately inside the doorThese can be used over a short-sleeve, non-melting shirt with a small logo in order to enter an MCC roomWhen finished, please return the jacket to where you found it
8 WR Mill Electrical Safety - Key Items Whenever doors to electrical enclosures are open, non-Qualified persons should stay back 10’Within 3’ of electrical panels located in the field, Cat 0 PPE is required. Many of these areas are marked with a “Keep Clear” zone.Additional areas that require 3’ clearance include lighting panels, welding outlets and local drive disconnects such as those on the sheeter decks.
9 WR Mill Electrical Safety - Key Items Example of signage that will be displayed on the outside of MCC rooms while switching or energizing of equipment is in progressBelt type barriers or Danger tape may also be used to restrict access to an areaTypically will be associated with Breaker testing activityDO NOT ENTER the roomEquipment in Room may be energized remotelyContact E&I Supervisor or Working Leaders if you have questionsRead
10 Operating Lighting Panel Breaker or Welding Outlet Note PPE:Long Sleeve, non-melting shirtStanding at arms length from panelFaced away from Lighting PanelEarplugsLeather glovesSafety glassesApplies to:Lighting PanelsWelding OutletsCrane DisconnectsLocal Disconnects
11 Key Points to WR Mill Electrical Safety Stay back 10’ from E&I Persons working on Live EquipmentCategory 0 apparel is required at all times in all MCC rooms and within 3’ of equipment located on the floorPlasticized designs over 4 X 4 inches are not permitted on or under the non-melting long sleeve shirtsMake sure you are wearing proper PPE when you operate lighting panel breakers or disconnect switchesIf you have any questions, the full policy can be found on SkillsNowMCC Rooms are not to be used as staging areas, break rooms or any other purposeOnly you can keep yourself safe
12 ONLY Electrically Qualified Workers Are Allowed Inside When Control Centers Are Being Worked On.You Must be Escorted by a Qualified Person to Enter.(Use slide w/narration and existing video)Only Electrically qualified workers are allowed inside when Motor Control Centers are being worked on.You must be escorted by a qualified person if you need to enter. The rules and protection requirements for compliance with NFPA 70E are required in all cases of working with or around electrical equipment. These rules require compliance to the labeled protection requirements for natural fiber clothing or arc rated clothing, hard hats and arc rated face shields.Contractors shall not use these areas as break rooms and they shall not be entered unless your work requires entry and then only when properly protected from arc flash hazards. Doorways to Motor Control Centers are labeled pertaining to clothing and other protective measures depending on the electrical task performed.
13 Arc Flash Protection Policy Contractors Operating MCC Disconnects – Non-electrical personnel shall not operate electricaldisconnects in MCC lineups.Protective Clothing Requirements – In order to enter a MCC Room, 100% natural fiber clothing(cotton) including long pants and long sleeved shirts are required. In order to operate a disconnector overload reset, leather gloves are required. A protective arc jacket or welding jacket can be wornover a 100% natural fiber short sleeve shirt or t-shirt. It is not permissible to wear nylon, rayon orother meltable fabric clothing under an arc rated protective jacket.Plasticized Clothing Designs – Any plasticized designs on shirts are limited to 4” by 4”. This includesshirts or t-shirts worn under arc rated jackets.MCC Room Limitations – When live electrical work is ongoing in an MCC Room such as breaker testing,the electrical personnel will display a DO NOT ENTER sign on the outside of the door(s). Do not enterthe MCC Room for any reason when this sign is displayed.Other MCC Lineups (outside of MCC Rooms) – For MCC lineups that are not in MCC Rooms, theprotective clothing requirements are necessary when within 36” of the electrical equipment.
14 Green Tags and Voltage Detectors Wisconsin Rapids MillThis section of class is intended to review some significant changes being implemented across the WR Mill to electrical control systems in order to reduce the risk of injury associated with energy isolation and lockout. This reduction of risk is based on assuring that when electrical systems are shutdown, electrical energy is shut off and isolated that equipment or machinery CAN NOT start while employees are working on the equipment or have their body in a position of danger.Green Tags and Voltage Detectors
15 Overview of Typical System This is a simple diagram of a typical electrical control system at the Mill. DCS stands for a distributed control system. PLC stands for a programmable logic control system.Notice at the top of the diagram where it says “current restart is accomplished here”. Currently when starters are shut off and locked out, a restart attempt is made to assure that the equipment the starter feeds will NOT start. The issue is that most of our electrical control system are programmed with what are called permissives or interlocks. In other words, systems are controlled so a pump will not run unless a certain auto valve is open. There are 1000’s of such examples. So …… if a restart attempt is made at operator interfaces (control panels) or even at most DCS Screens, there is no assurance that the equipment will not run due to the electrical starter being switched off or an interlock or permissive is keeping it from running. The key is for proper lockout we need to ASSURE that the equipment energy is isolated and CAN NOT start. NOTE – 14 PM DCS is the only system in the mill specifically setup to allow interlocks to be by passed.Existing restart attempts can be made by forcing PLC outputs to bypass interlocks but doing so does not account for potential communication issues between the PLC and the I/O (input – output systems)Notice the Green Tag on the diagram. A “green tag” is a special tag used at the WR Mill to positively identify source of electrical energy from a motor starter in a Motor Control Center (MCC) to the use of the electrical energy such as a motor. This tag is applied ONLY by a qualified electrician and only after he or she has TESTED the physical cable to the motor starter and has documented as such. In other words this proves that a direct electrical connection exists between any motor and the started that controls energy to that specific motor. Matching green tags are applied. One to the motor leads and the other on the MCC Starter Bucket. If we match the green tag at the motor and the MCC Starter and shut off the power, we have effectively isolated the electrical energy and we are assured that the motor CAN NOT restart.Notice the pink square. This represents a voltage detector that is applied to the door of the MCC Starter Disconnect. The purpose of the voltage detector is to verify that the disconnect switch operated properly and the energy to the starter/motor is OFF.
16 Verification of Energy Isolation for Lock Out It is necessary to change the procedure in HOW electrical energy is isolated to insure the safety of employees and contractors as well as to meet the OSHA definition (“Can Not Re-start”) is metInterpretation:Assure a direct electrical connection (GREEN TAGS)Visual verification of all three (3) phases of electrical energy is disconnected (VIEWING WINDOW or VOLTAGE DETECTOR TRANSITION FROM ON TO OFF)Provide a means to assure the absence of voltage (VOLTAGE DETECTOR)Consider any and all interlocks and by-passesIf necessary, perform a re-start (try) attemptThis slide represents our direction as a mill going forward pertaining to the verification of energy isolation for lockout.READ
17 Box Lockout with Procedure Procedure - Green Tags and Voltage Detector are both Installed:Lockout List/Procedure is generated ahead of timeCheck Green Tag at Motor Conduit against Lockout List (can be done ahead of lockout)Verify Tag on Bucket against the Lockout ListVerify all 3 phase lights on Voltage Detector are IlluminatedOpen DisconnectVerify all 3 phase lights on Voltage Detector go offApply LockNo Restart NeededWhen green tags and voltage detectors are completed on systems in the next year, this is the procedure that will be utilized (READ)
18 Green Motor/Starter Tag and Voltage Detector Typical for 480V MCC and motorsGreen tag will be on both the MCC bucket and motor on all new installationsSome previously installed installations (like this one) will have a green tag only at the motor, but will have a “Verified” label on the starter doorThe middle arrow shows the voltage detector.All 3 phase lights on the voltage detector must be on to begin with.The upper left picture shows a green tag applied to the cable leads to a motor.On the right, is a picture of a voltage detector with red LED lights showing that the energy is ON as evidenced by the red lights. Each of these lights represent the three (3) phases of electrical energy connected to the starter from the electrical bus bar. So ….when the disconnect is shut off, the three (3) stabs of the disconnect switch are effectively pulled out, the three (3) voltage detector lights go out or off. In this manner we are assured that the disconnect switch worked properly and the energy to the starter and to the motor is isolated.
19 MV Starter Installation Applications over 1000V require a slightly different approachThe voltage detectors are mounted inside the starterViewing windows are added so the status of the detectors can be seenThe covers on this IR window are threaded, so they screw on and off with no toolsAlthough the window is designed to withstand an arc, the cover should always be left in place when not in use to provide mechanical protection for the window
20 MV Starter Installation By looking through the window, you can see the voltage detectors for all 3 phasesThe lights will flash at different rates because they are capacitively coupled to groundJust like the voltage detectors installed in 480V MCC, these are insufficient for use to create an Electrically Safe Work Condition for E&I personnel
21 New Motor Verification Tag The existing Restart Tag will be replaced with a new Verification TagIt will have lines that reflect the new lockout procdureA DRAFT version is shown to the right
22 Wisconsin Rapids Mill Planned Power Outages This is the last section of this class where we will switch gears and perform a brief review of efforts underway across the mill to segregate/separate PIT and pedestrians.Planned Power Outages22
23 Known Power Outages#1 (West) Woodroom 4 hours, Monday June 10th starting at 7:00 AM#2 (East) Woodroom 8 hours, Monday, June 10th starting at 7:00 AMSouth Lime Kiln Area, 8 hours, Tuesday, June 11th starting at 7:00 AMNorth Lime Kiln Area, 30 minutes, Wednesday, June 12th, Starting at 12:00 PM#93 WM area, either June 17 or 18 if repair parts available in timeLikely to be other small outages to make hot-spot repairs. These will be done during breaks if there is a possibility of losing lights.
24 Powered Industrial Truck – Pedestrian Safety Wisconsin Rapids MillThis is the last section of this class where we will switch gears and perform a brief review of efforts underway across the mill to segregate/separate PIT and pedestrians.Powered Industrial Truck – Pedestrian Safety
25 Hazards of Powered Industrial Trucks (PITs) Now you see himNow you don’tOne of the hazards is the restricted vision of the PIT operator.This picture illustrates how the mast totally obstructs the operators view of the pedestrian.Pedestrians cannot assume they are seen by operators. Make eye contact before approaching or crossing the path of a PIT.This short video demonstrates this issue.2525
26 Exposure Control Methods Eliminate ExposureIsolate ExposureMinimize or Reduce ExposureHOW?Separate vehicle and pedestrian traffic by using multiple control methods to significantly reduce risk of injuryPeriodically evaluate pedestrian and traffic flow patterns to ensure controls are in placeAnnually train all employees in traffic control methods, rules, proceduresLimit Speed to 5mphThese control methods are in order of most protective to least protective. The following slides explain each method.2626
27 Minimize/Reduce Exposure Yellow Lines are used to define PIT lanesThey highlight frequently used PIT traffic lanes through pedestrian areasThey raise pedestrian awareness of frequent PIT trafficPedestrians can step/walk between yellow lines with caution, but should avoid them as much as possible.2727
28 Minimize/Reduce Exposure White lines are to define pedestrian walkways.They highlight walkways through high PIT traffic areasThey reduce exposure by directing pedestrian traffic along a designated walkway.PITs may be operated in pedestrian walkways when cones, barriers, or other warnings are placed in the walkway.2828
29 Minimize/Reduce Exposure Orange lines may be used by pedestrians and PITsPedestrians must use extreme caution if they have to walk between orange lines when the orange lights are activated. But should avoid walking between the lines when the lights are activated if at all possible.Orange lines/ lights are used in areas that:are too narrow to accommodate both pedestrian and PIT traffic, orare very visibly restricted for both the driver and pedestrian2929
30 Segregation of Pedestrians and Powered Industrial Trucks Policy Pedestrian ResponsibilitiesConform to signageWalk in designated pedestrian walkways while passing through the area (white lines)Use extreme caution if you have to enter an orange line area when orange lights are onMake eye contact with the PIT operator while approaching the truckWalk through mandoors, rather than overhead doors, when provided3030
31 Segregation of Pedestrians and Powered Industrial Trucks Policy PIT Operator ResponsibilitiesConform to signageOperate PIT’s in designated aisle ways while passing through the area (Yellow Lines)Drive with Extreme Caution when operating PIT’s between orange linesSound horns and slowing down at corners and doorwaysStop at pedestrian crosswalks when pedestrians are at the crosswalk, and stopping at stop signs3131
32 Wisconsin Rapids Mill Emergency Procedures This is the last section of this class where we will switch gears and perform a brief review of efforts underway across the mill to segregate/separate PIT and pedestrians.Emergency Procedures
33 Emergency Preparedness Emergency Phone NumbersFIRST call 911 then call (Plant Protection)Congregation AreaMaps with congregation areas and door numbersFirst AidInternal Medical First Responders have pagers and will respondAmbulance reporting to F&E will come in at Wilson StAmbulance reporting to Converting, 14PM & 16PM will come through the guard shackSevere WeatherTornado shelters, Storm Warnings
34 Work Awareness Permits Wisconsin Rapids MillThis is the last section of this class where we will switch gears and perform a brief review of efforts underway across the mill to segregate/separate PIT and pedestrians.Work Awareness Permits
35 Work Awareness Permit Fiber & Energy Prior to starting any work at F&E, the maintenance crews must get a WAP from the owning departmentA field inspection will be conducted with the owning department
36 Wisconsin Rapids Mill Line Breaking This is the last section of this class where we will switch gears and perform a brief review of efforts underway across the mill to segregate/separate PIT and pedestrians.Line Breaking
37 Line Breaking/Equipment Opening Line Breaking ProceduresDefinedLine Breaking/Equipment OpeningThe initial opening to the atmosphere a piping system, vessel, tank pump or other equipment normally containing hazardous materials, temperature or pressure by means of power tools, cutting torch or hand tools. Opening man-ways on tanks or other vessels is defined as line breaking and subject to all safety procedures. This definition dose not apply to opening a drain or pressure relief valve routed to a safe locationHazardous Materials and/or Energy:Temperature >120 deg. F or <-10 deg. FPh of <6 or >8 (corrosive to eyes and skin)Pressure > 30psigGaseous materials or solid materials >100#All flammable liquids or solidsElectrical (static or live) or radioactive energy
38 Line Breaking Procedures - PPE Personal Protective Equipment (PPE) necessary for protection shall be worn by all persons in the immediate area of the “breaking” and continued to be worn until there is no chance of a blockage or release of pressure or hazardous material or temperature (no hazard)Selection of proper PPE will be based on the potential hazardThe area where the “breaking” is to occur will be isolated and/or barricaded as necessary to protect all personnel in the area or who may enter the areaObtain a Work Awareness Permit and check all precautions necessary to isolate the system and purge all hazardous substances and verify a zero energy state (temperature/pressure/chemical)
39 Changes to WAP Permit/Procedure Work Awareness PermitChanges to WAP Permit/ProcedureUse Chemical Hazard Matrix to ID PPE Requirements Routinely versus just for shutdownsInclude a copy of the matrix with the WAP for Maintenance and ContractorsRequired PPE MUST be worn when line breaking/equipment opening
40 Line Breaking Further Defined If the hazardous substance contained in the system is flammable or combustible or corrosive, flushing with water is required. This is especially important for opening to atmosphere by means of a torch or electrically operated power tool. Flushing shall consist of blowing the system back to a tank of reservoir.Close all header/branch valves (LO)Always consider head pressure, low points and the potential for blockageUnions or flanges shall be opening slowly away from you to bleed potential pressureDrain valves shall be opened and rodded out to check for blockage
41 Vessel Opening (Line Breaking) Verification of Empty Verification of empty of a closed system requires confidence based on visual reference of being drained and/or trusted measurement. Drain verification is a part of the Box Lockout Checklist as:Drain Verification Complete by:Drain Rodded OutVisual Check – Top of Tank or VesselTrusted Level / Pressure IndicationDrain Bagged by PipefitterDrain Backflushed with Seal WaterAll Drains OpenOtherNOTE: Physically tag all tanks with multiple drains and add to specificLockout procedures