Transcript Wisconsin Rapids Mill

Specific Safety Procedures
Wisconsin Rapids Mill of NewPage
Wisconsin Rapids Mill
Electrical Safety Training
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 required
• Using appropriate personal protective equipment
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What is Arc Flash?
• Electrical Fault Through Air
• Temperatures can reach 35,000
°F (Oxyacetylene ≈ 6000 °F)
• Copper instantly vaporizes
- Expands 67,000 times from
solid to gas
- Mechanical forces similar to
dynamite
• Molten Metal and Shrapnel
Released
• Pressure Wave
• Intense Light (Similar to Welding)
• Loud Sound (> 140 dB)
• An Electric Arc Furnace is
essentially a controlled arc flash
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Summary of WR Mill Electrical Safety Policy
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Category 0 apparel will be required to enter an MCC Room at all times
for all personnel
Category 0 apparel consists of:
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All 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.
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100% non-melting clothes (cotton, wool)
Cotton Underclothes
Long Pants, Long Sleeves
Includes Local Disconnects for slitters, Welding Outlets, Lighting Panel
breakers
Any plasticized designs on clothing limited to 4” x 4”
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Burns > 30% of body reduce survival chances
Includes clothing worn under Arc Rated clothes
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Examples of non-melting shirts with designs
• OK
•NOT OK
(Under long sleeves)
•OK
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WR Mill Electrical Safety - Key Items
• Many MCC rooms have green
welders jackets either located
outside the room, or immediately
inside the door
• These can be used over a shortsleeve, non-melting shirt with a
small logo in order to enter an MCC
room
• When finished, please return the
jacket to where you found it
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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.
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 progress
• Belt type barriers or Danger
tape may also be used to
restrict access to an area
• Typically will be associated
with Breaker testing activity
• DO NOT ENTER the room
• Equipment in Room may be
energized remotely
• Contact E&I Supervisor or
Working Leaders if you have
questions
Operating Lighting Panel Breaker or Welding Outlet
Note PPE:
• Long Sleeve, non-melting shirt
• Standing at arms length from panel
• Faced away from Lighting Panel
• Earplugs
• Leather gloves
• Safety glasses
• Applies to:
• Lighting Panels
• Welding Outlets
• Crane Disconnects
• Local Disconnects
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Key Points to WR Mill Electrical Safety
• Stay back 10’ from E&I Persons working on Live Equipment
• Category 0 apparel is required at all times in all MCC rooms and within 3’ of
equipment located on the floor
• Plasticized designs over 4 X 4 inches are not permitted on or under the
non-melting long sleeve shirts
• Make sure you are wearing proper PPE when you operate lighting panel
breakers or disconnect switches
• If you have any questions, the full policy can be found on SkillsNow
• MCC Rooms are not to be used as staging areas, break rooms or any other
purpose
• Only you can keep yourself safe
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Arc Flash Protection Policy
Contractors Operating MCC Disconnects – Non-electrical personnel shall not operate electrical
disconnects 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 disconnect
or overload reset, leather gloves are required. A protective arc jacket or welding jacket can be worn
over a 100% natural fiber short sleeve shirt or t-shirt. It is not permissible to wear nylon, rayon or
other meltable fabric clothing under an arc rated protective jacket.
Plasticized Clothing Designs – Any plasticized designs on shirts are limited to 4” by 4”. This includes
shirts 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 enter
the 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, the
protective clothing requirements are necessary when within 36” of the electrical equipment.
Wisconsin Rapids Mill
Green Tags and Voltage Detectors
Overview of Typical System
Operator Interface
(Touchscreen,
Keyboard, Mouse, etc.)
CURRENT RESTART IS
ACCOMPLISHED HERE
DCS
Comm Link
Comm Link
DCS I/O
Operator Interface
(Pushbuttons,
Touchscreen,
Keyboard, Mouse, etc.)
PLC
Comm Link
PLC I/O
Pushbuttons,
Valves,
Lights,
Limitswitches,
Etc.
Physical Cable
Valves,
Transmitters,
etc.
MOTOR
STARTER
Physical Cable
THE VOLTAGE
DETECTOR IS APPLIED
AT THE DISCONNECT
GREEN TAG APPLIES
TO THE PHYSICAL
CONNECTION
BETWEEN THE
STARTER AND MOTOR
MOTOR
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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 met
Interpretation:
1. Assure a direct electrical connection (GREEN TAGS)
2. Visual verification of all three (3) phases of electrical energy is
disconnected (VIEWING WINDOW or VOLTAGE DETECTOR
TRANSITION FROM ON TO OFF)
3. Provide a means to assure the absence of voltage (VOLTAGE
DETECTOR)
4. Consider any and all interlocks and by-passes
5. If necessary, perform a re-start (try) attempt
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Box Lockout with Procedure
Procedure - Green Tags and Voltage Detector are both Installed:
1.Lockout List/Procedure is generated ahead of time
2.Check Green Tag at Motor Conduit against Lockout List
(can be done ahead of lockout)
3.Verify Tag on Bucket against the Lockout List
4.Verify all 3 phase lights on Voltage Detector are Illuminated
5.Open Disconnect
6.Verify all 3 phase lights on Voltage Detector go off
7.Apply Lock
8.No Restart Needed
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Green Motor/Starter Tag and Voltage Detector
• Typical for 480V MCC and motors
• Green tag will be on both the MCC
bucket and motor on all new
installations
• Some previously installed installations
(like this one) will have a green tag
only at the motor, but will have a
“Verified” label on the starter door
• The middle arrow shows the voltage
detector.
• All 3 phase lights on the voltage
detector must be on to begin with.
MV Starter Installation
• Applications over 1000V
require a slightly different
approach
• The voltage detectors are
mounted inside the starter
• Viewing windows are added so
the status of the detectors can
be seen
• The covers on this IR window
are threaded, so they screw on
and off with no tools
• Although 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
MV Starter Installation
• By looking through the window, you can see the voltage detectors for all 3 phases
• The lights will flash at different rates because they are capacitively coupled to
ground
• Just like the voltage detectors installed in 480V MCC, these are insufficient for use
to create an Electrically Safe Work Condition for E&I personnel
New Motor Verification Tag
• The existing Restart Tag will be
replaced with a new Verification Tag
• It will have lines that reflect the new
lockout procdure
• A DRAFT version is shown to the
right
Wisconsin Rapids Mill
Planned Power Outages
Known Power Outages
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#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 AM
South Lime Kiln Area, 8 hours, Tuesday, June 11th starting at 7:00 AM
North 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 time
• Likely to be other small outages to make hot-spot repairs. These will be
done during breaks if there is a possibility of losing lights.
Wisconsin Rapids Mill
Powered Industrial Truck – Pedestrian Safety
Hazards of Powered Industrial Trucks (PITs)
Now you see him
Now you don’t
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Exposure Control Methods
1.
Eliminate Exposure
2.
Isolate Exposure
3.
Minimize or Reduce Exposure
HOW?
• Separate vehicle and pedestrian traffic by using multiple control methods
to significantly reduce risk of injury
• Periodically evaluate pedestrian and traffic flow patterns to ensure
controls are in place
• Annually train all employees in traffic control methods, rules, procedures
• Limit Speed to 5mph
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Minimize/Reduce Exposure
Yellow Lines are used to define PIT lanes
• They highlight frequently used PIT traffic
lanes through pedestrian areas
• They raise pedestrian awareness of frequent
PIT traffic
• Pedestrians can step/walk between yellow
lines with caution, but should avoid them as
much as possible.
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Minimize/Reduce Exposure
White lines are to define pedestrian walkways.
• They highlight walkways through high PIT traffic
areas
• They 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.
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Minimize/Reduce Exposure
Orange lines may be used by pedestrians and PITs
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Pedestrians 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.
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Orange lines/ lights are used in areas that:
 are too narrow to accommodate both
pedestrian and PIT traffic, or
 are very visibly restricted for both the driver
and pedestrian
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Segregation of Pedestrians and Powered Industrial Trucks Policy
Pedestrian Responsibilities
• Conform to signage
• Walk 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 on
• Make eye contact with the PIT operator while approaching the truck
Walk through mandoors, rather than overhead doors, when provided
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Segregation of Pedestrians and Powered Industrial Trucks Policy
PIT Operator Responsibilities
• Conform to signage
• Operate PIT’s in designated aisle ways while passing through the area
(Yellow Lines)
• Drive with Extreme Caution when operating PIT’s between orange lines
• Sound horns and slowing down at corners and doorways
• Stop at pedestrian crosswalks when pedestrians are at the crosswalk,
and stopping at stop signs
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Wisconsin Rapids Mill
Emergency Procedures
Emergency Preparedness
• Emergency Phone Numbers
• FIRST call 911 then call 715.422.3333 (Plant Protection)
• Congregation Area
• Maps with congregation areas and door numbers
• First Aid
• Internal Medical First Responders have pagers and will respond
• Ambulance reporting to F&E will come in at Wilson St
• Ambulance reporting to Converting, 14PM & 16PM will come through the
guard shack
• Severe Weather
• Tornado shelters, Storm Warnings
Wisconsin Rapids Mill
Work Awareness Permits
Work Awareness Permit
Fiber & Energy
Prior to starting
any work at F&E,
the maintenance
crews must get a
WAP from the
owning
department
A field inspection
will be conducted
with the owning
department
Wisconsin Rapids Mill
Line Breaking
Defined
Line
Breaking Procedures
Line Breaking/Equipment Opening
The 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 location
Hazardous Materials and/or Energy:
• Temperature >120 deg. F or <-10 deg. F
• Ph of <6 or >8 (corrosive to eyes and skin)
• Pressure > 30psig
• Gaseous materials or solid materials >100#
• All flammable liquids or solids
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• Electrical (static or live) or radioactive energy
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 hazard
• The 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 area
• Obtain 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)
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Work Awareness Permit
Changes to WAP Permit/Procedure
 Use Chemical Hazard Matrix to ID PPE Requirements Routinely
versus just for shutdowns
 Include a copy of the matrix with the WAP for Maintenance and
Contractors
 Required PPE MUST be worn when line breaking/equipment
opening
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Further Defined
Line Breaking
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 blockage
• Unions or flanges shall be opening slowly away from you to bleed
potential pressure
• Drain valves shall be opened and rodded out to check for blockage
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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 Out
Visual Check – Top of Tank or Vessel
Trusted Level / Pressure Indication
Drain Bagged by Pipefitter
Drain Backflushed with Seal Water
All Drains Open
Other
NOTE: Physically tag all tanks with multiple drains and add to specific
Lockout procedures
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