PCS Phosphate Aurora

Transcription

1 PCS Phosphate Aurora

2 DFP Brick outage April 28-30, 2015 Safety Specialist: Dallas Foreman Cell Safety Rover Cell

3 Agenda Safety Policies ID Badges Eating/Drinking Evacuation / EBAs / Parking Plan Ambulance Pick Up Point Blue Signs Housekeeping Barricading Rigging / Crane / Man Lifts / Equipment Safe Work Practices Injury Reporting PPE Fall Protection Respiratory Protection Heat Stress Safe Work Permits / Pre-Task Plans Hot Work Requirements Confined Space Requirements Cord/Hand Tool Inspection Special Conditions

4 Safety Policies Safety Audits PCS Management Contractor Management Safety Observations Members of the Safety Department Exposure based safety Observations Members of the Exposure based Safety Program PCS and Contractors

5 General Safety Practices ID Badges Must be worn on chest when possible, otherwise kept on person Eating and Drinking: Food and drink are not permitted within the plant Water coolers/cups are available in the work areas, tape and date your coolers Properly dispose of water bottles. No consumption of food or freeze pops within the plant PLEASE stay within the confines DFP.

6 General Safety Practices Cell Phone Use Plantwide To enhance everyone s safety at Aurora, personal cell phone usage is restricted. Personnel may only use their personal cell phones during scheduled breaks and lunch. No personal cell phones are allowed in the work area (plant boundaries, tank farms, conveyor systems, rail yards, equipment, etc ). Personal cell phones must be left in your office, lunchbox, locker or personal vehicle. Employees may check for messages and use personal cell phones during scheduled breaks or lunch only. If family members need to contact employees due to an emergency, the number to call is Calls will be directed appropriately. Drivers must not answer or dial any phone numbers, including one button or voice activated dialing, while driving a motorized vehicle. The motorized vehicle must be parked in a safe and secure area before use.

7 General Safety Practices Open Holes: MUST be Guarded or Covered Covers MUST be secure Capable of Supporting (WITHOUT FAILURE) Twice the Expected Load of Personnel & Materials AT ONE TIME MUST be Labeled OPEN HOLE

8 Evacuation Routes/Parking Park personal vehicles in designated parking lots only Please do not block roadways or means of emergency exit with vehicles or equipment Follow the POSTED Speed Limits

9 Housekeeping Please do not throw: Cigarettes Spent welding rods Trash* ANY PPE on the ground *Please remember that all food wrappers, water bottles,freeze pops etc. MUST be placed in COVERED trash containers Smoking IS NOT permitted within : Break Rooms Offices Restrooms Smoking is ONLY permitted in designated Smoking areas.

10 Housekeeping Please keep tripping hazards, such as: Hoses Electrical Cords Welding Leads Equipment Cords out of walkways

11 Tags and Barricades Red tape indicates DANGER Use a DANGER tag every side and every 20 feet to identify: Specific Hazard Date of Application (good for 7 days or get a deviation) Name of Individual Applying tape/tag Company for Whom the Individual Works tape indicates CAUTION Use a CAUTION tag every 20 feet and include the same information as the DANGER tag Tape must be maintained PLEASE REMOVE ALL BARRICADE TAPE WHEN THE JOB IS FINISHED!

12 Rigging/Crane/Equipment Safe Work Practices Working Under Suspended Loads-NOT PERMITTED Unacceptable Rigging Practices: Rigging through Grating to Pry Bars Rigging to Handrails Riggers MUST Verify Load Capability/Capacity Rigging Equipment MUST be Inspected PRIOR TO USE

13 Manlift Equipment/Operator Safe Work Practices Equipment Use: Delivery Inspections: MUST be Conducted by authorized PCS employee when received on site prior to any use MUST be Present on Equipment during Shift Equipment Use: Pre-Shift Inspections: MUST be Conducted for EVERY Shift MUST be Present on Equipment during Shift Equipment Operation: All Operators MUST have Proper Certification/Licensure to Operate Equipment on PCS Phosphate Property Safety Chains MUST be Used when Towing

14 Rigging/Crane/Equipment Lockout/Tagout: Safe Work Practices IF Riggers/Equipment (Crane) Operators are in Contact with Locked Out Equipment: MUST Sign Safe Work Permit MUST Attach Personal Safety Lock to Lockbox Associated with the job Critical Lift Plan: ALL Critical Lifts REQUIRE Completion of PCS Phosphate Critical Lift Plan All Critical Lifts have been Previously Identified, but each lift shall be evaluated

15 Rigging/Crane/Equipment Safe Work Practices Equipment Use: Pre-Shift Inspections: MUST be Conducted for EVERY Shift MUST be Present on Equipment during Shift Equipment Operation: All Operators MUST have Proper Certification/Licensure to Operate Equipment on PCS Phosphate Property Safety Chains MUST be Used when Towing

16 Incident/Injury Reporting ALL Incidents and Injuries MUST be reported Any Environmental releases! Emergency Communications: UNIT 75-Security, Main Gate Facility-Wide Radio Channel 1A Safety Extension 777: In-Plant Telephones Extension 555: In-Plant telephones for Environmental Cell Phones dial for injuries or emergencies Cell Phones dial for Environmental Issues Be Prepared to Provide: Name and Location of Person Calling Type of Emergency Stand by for Further Instructions Have someone available to direct emergency vehicles to

17 Personal Protective Equipment (PPE) Hand Safety: Work Gloves-Part of Standard PPE Appropriate to Work Tasks Cut-Resistant ANY TIME blades or sharp edged materials are being used (Cut RESISTANT, not Cut PROOF) Ring Policy: MUST be removed when in areas requiring PPE Eye Protection: ANSI-Approved Safety Glasses with Sideshields Clear vs. Dark Tinted Lenses Must have goggles at all times (generally worn on hard hat) Do not wait to be told to wear them if in potential drip areas or high wind. Hearing Protection: Required within Battery Limits of Plant

18 H 2 S Monitors: 1 Monitor is required for each Contractor and PCS Employee. It MUST be Bump Tested Daily PRIOR TO Use and document EACH bump test. H 2 S Monitor Alarm Response MUST Immediately Evacuate Area by Moving Upwind Always Be Aware of Wind Direction Throughout the Day Production or Maintenance Supervisor Makes Determination to Allow for Re-Entry without PPE All contractors working in DFP must have completed H2S Training and have documentation on site.

19 Personal Protective Equipment (PPE) SP206 - Fall Protection - Trauma suspension straps are required SP208 - JHA s/ PTP s - Are required for all work. SP221 - Puncture resistant insoles are required. SP260 - Fixed blade knives are banned unless a deviation is obtained

20 REQUIRED: Fall Protection When Employees Exposed to a POTENTIAL Fall of GREATER THAN FOUR (4) FEET in Height IF Working from a Portable Ladder: User MUST Have THREE (3) POINTS OF CONTACT User s Center of Gravity MUST Remain Between the Rails of the Ladder User s Actions MUST NOT Push or Pull the Body from the Ladder OTHERWISE, Fall Protection MUST Be Used Trauma suspension straps are required!

21 Fall Protection Anchorage Points: Anchor points have been previously identified during Fall Protection Assessment MUST be rated for 5000 lbs. PER PERSON No pelican hooks! UNACCEPTABLE Anchorage Points: Handrails No standing on mid or top rails Cable Trays Conduit Piping ALL Fiberglass ALL HDPE (High Density Polyethylene) Piping ANY Steel Pipe LESS THAN 12 inch in diameter Steel pipe GREATER THAN 12 inches in diameter may be used UPON APPROVAL ONLY!!

22 Scaffolding Scaffolding Must Be Inspected at the start of each shift prior to use. All scaffold users must have completed Scaffold Users Training All scaffold modifications must be overseen by a competent person

23 Walking Surfaces Wet / Slick conditions Rain Wash down Snow / Ice Uneven surfaces Material buildup Shoe / boot condition

24 Respiratory Protection Definition of Clean Shaven Clean shaven means anywhere the face piece seal touches the face: At PCS this means a mustache that ends at the corners of your mouth and a small patch under your bottom lip. Facial Hair CANNOT Interfere with Respirator valve function (like long mustaches) You must wear respiratory protection for stainless steel activity in a confined space If Your Job Requires the Use of a Respirator: MUST be Fit-Tested MUST Participate in a Respiratory Protection Program

25 Heat stress See safety practice 235 for additional information. Drink plenty of fluids stay hydrated! For confined spaces where temperatures exceed 120 o F, cooling to below 120º F is required before work begins. Working in any areas, or outside confined spaces, between 110 o F and 120 o F, shall be approved by the Safety Manager or designee.

26 Pre Task Plan (PTP) A PTP is required to be complete d by all contract crews before each job. All members of the crew must sign the PTP

27 A JHA is required to be completed by all contract crews before each job. All members of the crew must sign the JHA Job hazard analysis (JHA)

28 Work Permits Safe Work Permits When Safe Work Permits are Required: Everyone Engaged in the Job MUST Sign the Permit All Signers MUST Use their Legal Names All Signatures MUST be Legible Permits MUST be Displayed at Job Site ALL Information MUST be Reviewed with ALL Those Working on the Job

29 Work Permits Safe Work Permits: Lockout/Tagout Individual Safety Locks: MUST be Properly Identified with Yellow/White Safety Lock tape All Locks MUST have a lockout tag that includes: Name of Lock Owner Company for Whom Lock Owner Works

30 Hot Work Requirements Abrasive blasting is Considered Hot Work Requires Properly Completed Safe Work Permit Overhead Hot Work Barricade ALL Areas Below with Danger Tape and Danger Tags Provide Contact to Allow Area Access Use Appropriate PPE for Hot Work Activities Be Sure to Remove, Wet or Cover ANY Flammable Materials within 35 feet of ANY Hot Work Issued with an area evacuation plan

31 Safe Work/ Hot Work Permits Must be filled prior to work beginning and must be legible by all.

32 Confined Space Entry Requirements ALL Confined Space Entry Participants MUST be Properly Trained on Their Duties Prior to Entry: Attendant Entrant Entry Supervisor VENTILATION REQUIREMENTS: Mechanical Ventilation REQUIRED for ALL Confined Space Entries Confined Space-Specific Ventilation Plan

33 Confined Space Entry Requirements Confined Space Permits EVERY Entry MUST be Documented on the Confined Space Permit Atmospheric Monitoring MUST be Conducted CONTINUOUSLY Back Up Battery or extra monitor if needed A/C Power Availability Monitoring Results MUST be Documented EVERY 30 MINUTES Monitors MUST be Calibrated MONTHLY BUMP TEST PRIOR TO EACH USE Document EACH Bump Test

34 Confined Space Entry Requirements Passage to the south of the kiln A flashing light and sign will be positioned at the foot point of the kiln. Before going past this point to the south end an attendant must be present to monitor the atmosphere. Contact will be made with the sign in attendant at the north end to request the south end attendant. All entries and exits will occur only at the north end of the kiln.

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36 Attendant & Supervisor Check Sheet

37 Confined Space Entry Requirements Confined Space Attendant/Entry Supervisor Responsibility Checksheets: MUST be Completed Initial Each Item ALL Confined Spaces MUST be Barricaded when NOT IN USE

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39 Confined Space Entry Requirements To Request Tech Rescue/EMT Team: UNIT 75-Security, Main Gate Facility-Wide Radio Channel 1A Safety Extension 777: In-Plant Telephones Cell phones dial Be Prepared to Provide: Name and Location of Person Calling Type of Emergency Have someone available to direct emergency vehicles to the scene Stand by for Further Instructions

40 Cord/Hand Tool Inspections ALL Cord Inspections MUST be Completed Prior to Use Current Color to Indicate Inspection Completion is Blue. Ground-Fault Circuit Interrupters (GFCIs) MUST be in Use Where Applicable Trigger Locks ARE NOT Permissible on Plantsite Equipment with Trigger locks: Must be Disabled -OR- Tagged OUT OF SERVICE

41 Special Conditions Sulfuric Acid Plant Startup Procedures Unit 75-Security, Main Gate-Announcement Practices: Plantwide PA System Facility-Wide Radio Channel 1A Safety

42 Plant Alarms If an Emergency Notification Alarm is sounded and you do not understand what the alarm means, come out of confined spaces, Down from manlifts, manbaskets, and upper levels of the plant and ASK what the alarm tone is for. An interpreter must be present with non- English speaking workers

43 Conclusion Stay in you designated work area If evacuation is necessary, go to the Evacuation Assembly Area. Know your foreman If you don t understand, ASK questions

44 Questions