Specific Safety Procedures Wisconsin Rapids Mill of NewPage.

Specific Safety Procedures

Wisconsin Rapids Mill of NewPage

Wisconsin Rapids Mill

Electrical Safety Training

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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

• Category 0 apparel will be required to enter an MCC Room at all times for all personnel

• Category 0 apparel consists of:• 100% non-melting clothes (cotton, wool)

• Cotton Underclothes

• Long Pants, Long Sleeves

• 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. • Includes Local Disconnects for slitters, Welding Outlets, Lighting Panel

breakers

• Any plasticized designs on clothing limited to 4” x 4”• 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(Under long sleeves)

•NOT OK

•OK

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• Many MCC rooms have green welders jackets either located outside the room, or immediately inside the door

• These can be used over a short-sleeve, 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

WR Mill Electrical Safety - Key Items

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

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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

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 disconnector 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 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, the protective clothing requirements are necessary when within 36” of the electrical equipment.

Arc Flash Protection Policy

Wisconsin Rapids Mill

Green Tags and Voltage Detectors

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Overview of Typical System

DCS PLC

PLC I/O

MOTOR STARTER

MOTOR

Physical Cable

Physical Cable

Comm Link

Operator Interface(Touchscreen,

Keyboard, Mouse, etc.)

Operator Interface(Pushbuttons, Touchscreen,

Keyboard, Mouse, etc.)

Comm Link

DCS I/O

Comm Link

Valves, Transmitters,

etc.

Pushbuttons,Valves,Lights,

Limitswitches, Etc.

GREEN TAG APPLIES TO THE PHYSICAL

CONNECTION BETWEEN THE

STARTER AND MOTOR

THE VOLTAGE DETECTOR IS APPLIED AT THE DISCONNECT

CURRENT RESTART IS ACCOMPLISHED HERE

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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

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

• #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

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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

• 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.

• 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

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

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Defined

Line 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 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

• Electrical (static or live) or radioactive energy

Line Breaking Procedures

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• 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)

Line Breaking Procedures - PPE

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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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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

Further Defined

Line Breaking

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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 OpenOther

NOTE: Physically tag all tanks with multiple drains and add to specific

Lockout procedures

Vessel Opening (Line Breaking) Verification of Empty