1. INTRODUCTION ................................................................................................................................................................. 8
A.
Internet Access ...................................................................................................................................................9
B.
Acknowledgements ............................................................................................................................................9
C.
Cover Back .........................................................................................................................................................9
D.
Policy ..................................................................................................................................................................9
E.
Our Mission.........................................................................................................................................................9
F.
Our Commitment ................................................................................................................................................9
G.
VPP Program....................................................................................................................................................10
H.
Purpose ............................................................................................................................................................10
I.
Point of Contact ................................................................................................................................................10
J.
Contractual Construction Safety Statement .....................................................................................................10
K.
Safety Qualification Requirements ...................................................................................................................11
2. CONTRACTOR TRAINING REQUIREMENTS ........................................................................ 11
A.
Site Safety & Security Orientation (updated)....................................................................................................11
B.
Verification of OSHA mandated training...........................................................................................................11
C.
Worker Safety and Health Program – 10 CFR 851 (new)................................................................................12
D.
Training Badges................................................................................................................................................12
E.
Occupational Safety & Health (OSHA) Training (updated) ..............................................................................13
F.
Certification of Training.....................................................................................................................................14
3. REFERENCES (updated)........................................................................................................ 15
A.
Federal Compliance Documents ......................................................................................................................15
B.
National Fire Protection Association Standards ...............................................................................................15
C.
Department of Energy Orders ..........................................................................................................................15
D.
Definitions .........................................................................................................................................................16
4.
FACILITIES ENGINEERING PROJECT COORDINATION.................................................. 17
5.
CONSTRUCTION SAFETY & HEALTH PROFESSIONAL (updated) ................................. 17
6.
ON SITE CONSTRUCTION SAFETY COMPETENT PERSON (new) ................................. 18
1
7.
SAFETY PROGRAM ELEMENTS (updated) ...................................................................... 18
A.
Cover page .......................................................................................................................................................18
B.
Qualification list.................................................................................................................................................19
C.
Activity Hazard Analysis ...................................................................................................................................19
D.
Medical Care Provider (new) ............................................................................................................................19
E.
Flow-Down Clause............................................................................................................................................19
F.
Weekly Safety Meetings ...................................................................................................................................19
G.
Hazardous Materials.........................................................................................................................................20
H.
Pollution Prevention..........................................................................................................................................20
I.
Daily Hazard Analysis.......................................................................................................................................20
J.
Demolition Activities..........................................................................................................................................20
8. SAFETY PROGRAM IMPLEMENTATION .............................................................................. 21
A.
Seller management leadership and employee participation in ES&H at KCP. ................................................21
B.
Hazard identification and assessment..............................................................................................................21
C.
New means and methods.................................................................................................................................21
D.
Hazard prevention and control at KCP.............................................................................................................21
E.
Safety information and employee training/qualification ....................................................................................22
F.
Periodic evaluation of program effectiveness...................................................................................................22
9. SAFETY INSPECTIONS & MEETINGS................................................................................... 22
A.
Facilities Engineering Inspections of the Construction Sites............................................................................22
B.
Inspections by NNSA/KCSO Personnel ...........................................................................................................22
C.
Inspections by Environment, Safety, and Health (ES&H) ................................................................................22
D.
Seller Inspections and Reviews........................................................................................................................22
E.
Monthly Superintendent Meetings ....................................................................................................................23
10. WARNING TICKETS & CITATIONS ..................................................................................... 23
2
A.
Warning Tickets ................................................................................................................................................23
B.
Citations ............................................................................................................................................................23
C.
Contract Remedies ...........................................................................................................................................24
D.
Sellers Disciplinary Process .............................................................................................................................24
E.
Employee Expulsion Policy ..............................................................................................................................24
11. REPORTING/POSTING REQUIREMENTS ........................................................................... 25
A.
Unforeseen Hazard Posting .............................................................................................................................25
B.
Accidents/Injuries/First aid cases .....................................................................................................................25
C.
Property Damage (updated) .............................................................................................................................25
D.
Tabulation of Work-Hours.................................................................................................................................25
E.
Posting Requirements ......................................................................................................................................25
F.
Posted Construction Areas...............................................................................................................................26
G.
Emergency Evacuations, Reporting and Medical Care (updated) ...................................................................26
H.
Equipment Identification/Removal from the plant.............................................................................................26
12. PERMITS (updated) .............................................................................................................. 27
A.
Types ................................................................................................................................................................27
B.
High Hazard Construction Safe Work Permits .................................................................................................27
C.
Utility Location & Excavation Permit.................................................................................................................28
E.
Life Safety Aisle/Exit Impairment Permits.........................................................................................................28
F.
Utility System Modification Permit ....................................................................................................................29
G.
Revocation of Permits ......................................................................................................................................29
13. ENVIRONMENTAL PROTECTION........................................................................................ 29
A.
Excavation Concerns........................................................................................................................................29
B.
Hazardous Waste .............................................................................................................................................29
C.
Equipment/Tools Decontamination ..................................................................................................................29
D.
Asbestos Abatement ........................................................................................................................................30
E.
Decontamination...............................................................................................................................................30
F.
Discharge to Drain Systems .............................................................................................................................30
G.
Storage of Hazardous Waste ...........................................................................................................................30
H.
Disposal of Hazardous Waste ..........................................................................................................................30
I.
Spills and Leaks................................................................................................................................................31
J.
Environmental Control ......................................................................................................................................31
K.
Dust Control......................................................................................................................................................31
L.
Visible Emissions..............................................................................................................................................31
M.
Prevention Guidelines ......................................................................................................................................31
N.
Transport of Equipment ....................................................................................................................................31
14. LIFE SAFETY ON CONSTRUCTION SITES ......................................................................... 32
3
15. FIRE PROTECTION .............................................................................................................. 32
A.
Fire Protection Equipment ................................................................................................................................32
B.
Aisle Blockage ..................................................................................................................................................32
C.
Fire Rated Walls ...............................................................................................................................................32
D.
Internal Combustion and Propane-Powered Vehicles and Equipment ............................................................33
E.
Flammable Liquid Storage and Use .................................................................................................................34
F.
Hot Work (Welding, Cutting, Grinding, or Spark-Producing Activities) ............................................................37
G.
Portable Heaters...............................................................................................................................................39
H.
Housekeeping...................................................................................................................................................40
I.
Storage of Combustible Materials ....................................................................................................................40
J.
Smoking Policy .................................................................................................................................................40
16. INDUSTRIAL HYGIENE & HEALTH PHYSICS..................................................................... 41
A.
Hazardous Material Sampling ..........................................................................................................................41
B.
Employee Protection Systems..........................................................................................................................41
C.
Ventilation and Dust Control.............................................................................................................................41
D.
Painting / Coating Application Guidelines ........................................................................................................42
E.
Noise.................................................................................................................................................................43
F.
Asbestos-Containing Material...........................................................................................................................43
G.
Non-Ionizing and Ionizing Radiation.................................................................................................................43
H.
Hazard Communication ....................................................................................................................................44
I.
Confined Space Entry.......................................................................................................................................44
J.
Hazardous Material Labeling Requirements ....................................................................................................45
K.
Lead ..................................................................................................................................................................45
L.
Beryllium Awareness ........................................................................................................................................46
M.
Beryllium Training .............................................................................................................................................46
N.
Beryllium Tools .................................................................................................................................................47
O.
Subcontractor Beryllium Workers .....................................................................................................................47
P.
Beryllium Worker Blood Test ............................................................................................................................48
Q.
Beryllium Air Monitoring....................................................................................................................................48
R.
Moving Equipment Used to Process Beryllium ................................................................................................49
17. MEDICAL SURVEILLANCE PROGRAM (new) .................................................................... 50
4
A.
Respirator Medical Monitoring Requirements ..................................................................................................50
B.
Audiometric Testing ..........................................................................................................................................50
C.
Additional OSHA Specific Medical Monitoring Requirements ..........................................................................50
D.
Hazardous Waste Operations / Clean Up ........................................................................................................50
E.
Asbestos Medical Monitoring Requirements ....................................................................................................50
18. SAFETY ................................................................................................................................ 51
A.
Personal Protective Equipment Requirements.................................................................................................51
B.
Overhead Work Hazards (New) .......................................................................................................................52
C.
Securing the Work Zone...................................................................................................................................52
D.
Safety Guardrails ..............................................................................................................................................53
E.
Moving Load Limits on Elevated Floor Slabs ...................................................................................................53
F.
Scaffold Tagging System..................................................................................................................................54
G.
Scaffolds ...........................................................................................................................................................55
H.
Ladders and Aerial Lifts....................................................................................................................................55
I.
Powder-Actuated Tools ....................................................................................................................................56
J.
Portable Air Compressors / Pressure Vessels (new) .......................................................................................56
K.
Plant Compressed Air Systems (new).............................................................................................................56
L.
Helicopter Lifts ..................................................................................................................................................56
M.
Cranes ..............................................................................................................................................................56
N.
Excavations ......................................................................................................................................................57
O.
Electrical Safety ................................................................................................................................................58
P.
In-Plant Vehicles (Powered Industrial Trucks and Carts).................................................................................60
Q.
Customized/Modified Heavy Equipment ..........................................................................................................60
R.
Motor Vehicles and Mechanized Equipment ....................................................................................................61
S.
Steam Systems.................................................................................................................................................61
19. DRILLING INTO CONCRETE OR ASPHALT (new) ............................................................. 61
A.
Penetrations Greater Than 4 Inches ................................................................................................................61
B.
Penetrations Less Than 4 Inches .....................................................................................................................61
20. ROOF WORK......................................................................................................................... 62
A.
Roof Work Notification......................................................................................................................................62
B.
Temperature Drop ............................................................................................................................................62
C.
Icy Conditions ...................................................................................................................................................62
D.
Roof Damage....................................................................................................................................................62
E.
Weight Restrictions...........................................................................................................................................62
F.
Roof Crane Use ................................................................................................................................................62
G.
Material Storage ...............................................................................................................................................63
H.
Roof Drains.......................................................................................................................................................63
I.
Vehicle Standards For Use On The Roof.........................................................................................................63
J.
How to Proceed When KCP Floor/Roof May be Penetrated............................................................................63
5
21. SECURITY REQUIREMENTS ............................................................................................... 65
A.
Security Badge Requirements (updated) .........................................................................................................65
B.
Physical Security ..............................................................................................................................................65
C.
General Security Awareness ............................................................................................................................65
D.
Badge Procedures ............................................................................................................................................66
E.
Building Access ................................................................................................................................................66
F.
Identification of Controlled and Prohibited Articles...........................................................................................67
G.
Protection of Unclassified Controlled Nuclear Information...............................................................................67
H.
Procedures for Reporting Safeguards and Security Concerns ........................................................................67
I.
Identification of Classification Markings ...........................................................................................................67
22. EQUIPMENT SUPPLIES AND DELIVERY............................................................................ 68
A.
MSB Deliveries (updated).................................................................................................................................68
23. WEATHER RESTRICTIONS ................................................................................................. 69
A.
Wind conditions: ...............................................................................................................................................69
B.
Lightning: ..........................................................................................................................................................69
C.
Ice/snow:...........................................................................................................................................................69
D.
Heat conditions: ................................................................................................................................................69
Appendix A Construction Safety Plan Outline (updated) ............................................................ 70
Appendix B Weekly Construction Safety Checklist..................................................................... 73
Appendix C Warning Ticket Example ......................................................................................... 76
Appendix D Citation Example ..................................................................................................... 77
Appendix E DOE F 5484.3 ........................................................................................................ 79
Appendix F Critical/Unusual Lift Plan.......................................................................................... 84
Appendix G Safety Requirements for Contractor Lockout/Tagout .............................................. 86
Appendix H Permit for Energized Electrical Task (PEET)........................................................... 98
Appendix I In-Plant Vehicle Operations Standards ................................................................... 102
Appendix J Safety Requirements for Airlifting Operations ........................................................ 107
6
Appendix K Helpful Telephone Numbers (updated) ................................................................. 112
Appendix M Construction Qualification Requirements (updated).............................................. 118
Appendix N Activity Hazard Analysis ........................................................................................ 121
Appendix O Daily Hazard Analysis........................................................................................... 123
Appendix P Safety Professional Responsibilities (updated)...................................................... 124
Appendix Q Penetration Checklist (new).................................................................................. 127
Appendix R Utility Location & Excavation Permit (updated)...................................................... 128
Appendix S Utilities Permit For Modification ........................................................................................................ 130
KANSAS CITY AREA MAP ....................................................................................................... 130
7
1. INTRODUCTION
Safety is our priority. At the Kansas City Plant, our concern for safety begins before the
start of your project. We launched a “Safety as a Lifestyle” campaign that encourages our
associates to approach safety as a vital and ever-present part of their daily lives. We look
to our construction contractors to strive for the same level of safety commitment.
The Kansas City Plant is committed to working with you to ensure a safe and healthful
workplace for both your employees and our associates. The Kansas City Plant has
proudly achieved star status in the Department of Energy Voluntary Protection Program
(VPP) and ISO 14001, the Environmental Management System Standard. With your help,
we can remain one of the safest and most environmentally friendly facilities in the DOE
community.
This handbook will assist you in producing a project-specific safety plan for construction
contract work to be performed for The Kansas City Plant.
This document is not intended to cover all aspects of a safety program, but it is intended to
provide guidelines to assist your company in developing a quality safety plan. Local
policies and practices can be added to these guidelines to provide a more practical vehicle
for each contractor’s immediate needs.
All Sellers shall take reasonable precautions under this contract to assure the safety and
health of KCP’s associates and assure the protection of plant operations from damage that
might result from construction activities.
It is the Seller's continuing and absolute responsibility for all aspects of construction safety
on their jobsite at the KCP. Any action or inaction by KCP’s or the NNSA or their
designated representative shall in no way alleviate Seller's responsibility or in any way
create liability on the part of the Buyer or the NNSA.
Notice: This handbook provides requirements and illustrations in effect on the date of
publication, February 2007. Requirements are subject to change without notice. If you
currently have an active construction project, you will receive changes and updates as they
become available.
8
A. Internet Access
If you are currently working at the Kansas City Plant and have computer access, this
handbook is available on-line. Through “Portal” home page under “Safe and Secure,”
click on “ES&H” then ”Contractor” to view the most up-to-date version of this handbook
as well as other safety and environmental information. You can also access the
handbook outside of the plant at www.kcp.com.
B. Acknowledgements
This book has been revised and edited with the assistance and input from the following
KCP organizations: Environmental Safety & Health, Facilities Engineering, Fire
Protection Services, Legal Services, Graphic Arts and Communications. Additionally,
the following contractors graciously provided their assistance: Facility Engineering
Services and Superior Electrical Construction. We are constantly striving to improve
the usefulness of this document to you, our customers. We welcome any comments or
suggestions you may have for our next printing. We can be reached in the Safety and
Health Department at (816) 997-5142.
C. Cover Back
Back Cover: FM&T’s Integrated Safety Management (ISM) logo: a common sense
approach to doing work safely. Treat safety as an equal and essential part of the job,
not as an add-on or afterthought. ISM’s approach tailors hazard control to the work
being performed. This is the key element to writing a successful site-specific safety
plan.
D. Policy
It is the policy at the Kansas City Plant (KCP) to assure that construction and
construction-related contracts comply with site-specific, federal, state, and local
requirements concerning safety, health, fire protection, and environmental protection
standards.
E. Our Mission
We will achieve a world class level of safety performance for contractors working at
Honeywell locations through increased safety awareness, communication of
expectations, and following work processes which reduce at-risk behaviors.
F. Our Commitment
We recognize that outstanding safety performance is essential to the welfare of all
associates, contractors and to business excellence. We will continue to improve our
global competitiveness by making safety an integral part of all business activities.
9
G. VPP Program
The KCP has proudly achieved star status in the Voluntary Protection Program (VPP)
which recognizes our employees and contractors for demonstrating the highest level of
safety and health performance. Under this program you have the right to participate in
safety and health issues at our facility, report or stop unsafe conditions, review accident
reports and take an active role in improving our safety and health program. We
encourage you to attend the various construction safety meetings held throughout the
year. Thanks again for making the KCP a national leader in safety and health.
H. Purpose
The following requirements shall be fulfilled by the contractor and each lower-tier
subcontractor (for the remainder of this document referred to collectively as "Seller"
when the requirements apply to either party).
I. Point of Contact
Our Buyer has designated the Project Engineer as the Seller's point of liaison for any
Seller activity described in this document as requiring any joint approvals by
Environment, Safety, and Health (ES&H).
J. Contractual Construction Safety Statement
In the event of an imminent danger violation (a condition or practice existing which
could reasonably be expected to cause death, serious physical harm, or extensive
environmental/property damage if it were not stopped), a Stop Work Order and Citation
will be issued to the Seller.
The following individuals are authorized to issue a Stop Work Order:
1. Purchasing on the recommendation of Facilities Engineering;
2. NNSA Contracting Officer;
3. ES&H associates (Fire Prevention, Health & Safety or Environmental Protection).
The Stop Work Order will be written by the Project Engineer. Verbal direction will be
given to stop work when an imminent danger condition exists.
The Seller will be notified when to resume work after a Stop Work Order has been
issued. The Seller shall make no claims for extensions of time or for compensation or
damages by reason of or in connection with such work stoppage.
KCP employees may also intervene if they see a construction contractor performing an
unsafe act.
10
K. Safety Qualification Requirements
The Kansas City Plant qualifies general contractors to assure that they meet
established safety criteria prior to being allowed to work and they are committed to
working safely while at the Kansas City Plant.
Qualification requirements are established in a two-step system. All general
contractors must meet the requirements of the first step (PART 1); Then complete part
on on-site visit of your facility (PART 2).
Contractors who pass the qualification process will be added to the KCP’s list of
qualified companies and will remain on the list until March 1 of the following year.
If a general contractor is under contract, they will remain qualified for the duration of
their contract.
The specifics of the two-step system are further defined in appendix M.
2. CONTRACTOR TRAINING REQUIREMENTS
A. Site Safety & Security Orientation (updated)
All personnel who will be working at the Kansas City Plant will be required to attend an
orientation class. The class is held every Monday at 9:00 a.m. Have your employees
arrive at the main entrance. (See map at back of book for plant location.)
Allow one and a half hours for the security badging and orientation class. If you are going
to be on site for a short time, three days or less, we will come directly to your work area
and present the orientation class.
Your project coordinator will arrange the orientation class. Any time you bring new
subcontract employees on-site you must notify the Safety Department to schedule an
orientation class. All new employees who will be on-site for one week or more must start
on Monday. Note: the orientation class schedule is subject to change. All affected
contractors will be notified on any schedule changes.
B. Verification of OSHA mandated training
All new construction employees and subcontractors whose companies have ten or more
employees shall submit for verification certificates or training records indicating they have
completed OSHA mandated training. Employees will not be allowed to attend orientation
class without bringing their training records. See sections D and E below for details.
11
C. Worker Safety and Health Program – 10 CFR 851 (new)
February 2007 the new worker safety and health program will go into effect. This
regulation requires NNSA contractors and subcontractors to comply with all OSHA safety
and health regulations. This handbook will assist you in meeting these requirements. The
DOE/NNSA may audit the seller’s activities to ensure compliance with the regulation. 10
CFR 851 can easily be accessed on the internet.
D. Training Badges
A safety and security orientation badge will be issued to all crafts who complete the class.
This card must be presented to the security guard when returning to gain access to the
plant. This card is proof that your employees and subcontractors have completed the site
safety and security orientation class. The new program started September 1, 2005. If you
are bringing in a subcontractor, check to see if they have training badges prior to their first
day of work.
Below is the procedure for forgotten or lost orientation badges.
Forgot Badge
• Your employee/sub contacts project superintendent and waits in guard shack.
• Superintendent calls extension 3181 and gives employee name.
• Superintendent comes down to ES&H at OB48 ½ to pick up temporary badge.
• Superintendent delivers badge to employee waiting in guard shack.
• Temporary badge will expire in 24 hours.
Lost Badge
• Your employee/sub contacts project superintendent and waits in guard shack.
• Superintendent calls extension 4040 and gives employee name.
• Superintendent comes down to ES&H at OB48 ½ to pick up replacement badge.
• Superintendent delivers badge to employee waiting in guard shack.
Details
• Third badge re-print due to loss results in warning ticket to general contractor.
• During emergency repair situations, employees will be allowed to work if they
forget their badge.
• No temporary or badge replacements will be issued on weekends or holidays or
outside normal business hours.
12
E. Occupational Safety & Health (OSHA) Training (updated)
The Seller (including lower tier subcontract employees) engaged in construction,
abatement or remediation activities that require OSHA or other applicable mandated
training and/or certification shall maintain documentation onsite, verifying completion of
required training.
All construction contractors coming on site must show proof of completing OSHA
mandated training prior to starting work at the Kansas City Plant. This requirement is an
expectation of The National Nuclear Security Administration (NNSA).
Everyone is required to have the two courses listed below:
•
Hazard Communications Training – 29 CFR 1910.1200, and 29 CFR 1926.59 (h)
(2) All employees must show proof of being trained in the Hazard Communication
Standard.
•
Ladder & Stairway Safety – 29 CFR 1926.1060 Training is required for each
employee using ladders and stairways.
Depending on your job tasks, your employees may need the following:
Please Note: This is only a short list of potentially required training bring any additional
OSHA or EPA mandated training you may have.
•
Fire Extinguisher Training – NFPA 51B standard for fire prevention during
welding, cutting and other hot work Any employee designated for fire watch
duty for hot work i.e. welding, cutting or spark producing activities must have this
training. Training shall include proper selection, use and application of
extinguisher agents, characteristics and classification of fires.
•
Confined Space - 1926.21 (b) (6) and 29 CFR 1910.146 any employee who will
be entering a confined space shall be trained.
•
Lockout/Tagout - 29 CFR 1910.147 (c) Any employee who will be working on
potentially energized, mechanical, temperature extreme or pressure systems
must be trained in Lockout/Tagout methods.
•
Powered Industrial Trucks (fork truck operator training) - 1910.178 (I) Any
employee who will be operating a forklift must have an operators permit showing
the employee has completed the training required by this standard.
•
Powder-Actuated Tools (ram set) – 29 CFR 1926.302 (e) If you will be using
a ram-set you must have you operators training card.
•
Respiratory Protection – 29 CFR 1926.103 Any employee who will require
respirator protection must be trained & fit tested with medical approval.
13
•
HAZWOPER – 1926.65 and 29 CFR 1910.120 Hazardous Waste And
Emergency Response Standard. The 40-hour training course and certification is
required of employees who will be performing hazards waste clean up or
working in regulated areas.
•
Asbestos Abatement– 29 CFR 1926.59 Any employee performing asbestos
abatement must show proof of completing an approved asbestos abatement
course.
•
Lead Abatement – 29 CFR 1926.62 and 29 CFR 1910.1025 and Missouri
regulation 10 CSR 30-70.150 - Any worker performing lead abatement must
show proof of completing a EPA approved Missouri Lead Abatement Worker
certificate.
F. Certification of Training
The written certification record shall contain the name of the employee trained, the date(s)
of training, and the signature of the person who conducted the training or the signature of
the employer. If the employer relies on training conducted by another employer. The
certification record shall indicate the date the employer determined the prior training was
adequate rather than the date of actual training.
We look forward to having you as a part of our construction team here at the Kansas City
plant. With your help, we can remain one of the safest and most environmentally friendly
facilities in the DOE community.
14
3. REFERENCES (updated)
These are a few selected references that may help you with preparing your site-specific safety
plan.
A. Federal Compliance Documents
•
Safety & Health record keeping required 300 & 300A logs (See www.osha.gov)
•
Safety and Health Regulations for Construction, Code of Federal Regulations
(CFR), Title 29, Part 1926
•
Chronic Beryllium Disease Prevention Program, 10 CFR Part 850
•
Occupational Safety and Health Standards, CFR, Title 29, Part 1910
•
Environmental Protection Agency Regulations, CFR, Title 40, Part 61, Subpart M,
National Emission Standard for Asbestos
•
Environmental Protection Agency Regulations, CFR, Title 40, Part 262, Subpart C,
Pre-transport Requirements for Hazardous Wastes
•
Department of Transportation Regulations (Parts 100-177)
•
Worker Safety and Health Program – 10 CFR 851
B. National Fire Protection Association Standards
•
NFPA 70-E Standard for Electrical Safety In The Workplace 2004 edition
•
NFPA 30
Flammable and Combustible Liquids Code
•
NFPA 33
Materials
Standard for Spray Application Using Flammable and Combustible
•
NFPA 241
Safeguarding Construction, Alteration and Demolition Operations
•
NFPA 70
National Electric Code
•
NFPA 51B Standard for Fire Prevention During Welding, Cutting and other hot
work 2003 edition
C. Department of Energy Orders
•
To review the current Department of Energy and NNSA requirements, see
www.directives.doe.gov
15
D. Definitions
Basic Contract definitions are included in the General Conditions and in the Terms and
Conditions of Purchase. In addition to these definitions, the following definitions apply to
this Construction Safety Handbook:
16
Area Owner
KCP representative with oversight responsibilities for the space in which
work is occurring.
Buyer
NNSA’s Kansas City Plant operated by Honeywell Federal
Manufacturing & Technologies LLC.
Seller
Corporation, partnership, joint venture, or individual which enters into a
purchase order with Honeywell FM&T.
Safety
Professional
Individual who has academic credentials or work experience in a
relevant discipline, such as environmental protection, industrial hygiene,
industrial safety or health physics and who has practical knowledge of
the work activities.
Competent
Person
One who is capable of identifying existing and predictable hazards in the
surroundings or working conditions which are unsanitary, hazardous, or
dangerous to employees, and who has authorization to take prompt
corrective measures to eliminate them.
Activity
Hazard
Analysis
A document that includes identification of principal work steps, site
hazard and controls, task hazards and controls and necessary permits
and training.
Daily Hazard
Analysis
A documented daily review of work tasks by a competent person with
crafts, identifying task-related hazards, controls, permitting
requirements, and validation of training associated with the work to be
performed. Crafts will sign document and post on job site daily.
DOE
United States Department of Energy. "DOE/AL" refers to the
Department of Energy, Albuquerque Operations.
ES&H
Buyer's Environment, Safety, and Health Division.
FES
Facility Engineering Services, LLC, a subsidiary of Burns and McDonnell
Engineering.
FM&T
The Kansas City Plant and Kirtland Operations, collectively managed by
Honeywell.
ISM
Integrated Safety Management. The 5 core functions of ISM are: 1)
Define scope of work. 2) Analyze the hazards 3) Develop & implement
controls. 4) Perform the work 5) Feedback & Improvement.
KCP
The Federal Complex at 2000 E. Bannister, Kansas City, Missouri. KCP
facilities are operated by the Buyer pursuant to a contract with the
Department of Energy.
LOTO
Lockout/Tagout Program, used to minimize risk of interaction between
workers and a dangerous energy source. The program is located in
appendix G.
NFPA
National Fire Protection Association.
NNSA
National Nuclear Security Administration, an agency of the Department
of Energy.
HHCSWP
High Hazard Construction Safe Work Permit (form 2953).
KCSO
Kansas City Site Operations.
Project
Engineer
The Project Engineer is the agent of the Buyer to the extent expressly
authorized by the purchase order documents and will, in general,
inspect, observe, and report concerning the work. The Project Engineer
is authorized to stop the work, whenever necessary in their opinion, to
ensure the safe and proper execution of the work. The Project Engineer
can be either a contract engineer or Honeywell associate.
Purchase
Order
Same as the term "contract" or "contract documents" and refers to the
purchase order issued between Seller and Buyer.
RCRA
Resource Conservation and Recovery Act.
4. FACILITIES ENGINEERING PROJECT COORDINATION
A checklist was developed to ensure no safety, health and environmental aspects of
construction planning will be overlooked. An example of this checklist is in Appendix L.
This checklist will be used by the Facilities Engineers and Planners.
5. CONSTRUCTION SAFETY & HEALTH PROFESSIONAL
(updated)
Depending on project size or scope The Kansas City Plant may require your project to be
staffed by a safety & health professional to provide direct oversight and maintain your
safety & health program while working at the Kansas City Plant. The safety professional
may also act as the on site construction safety competent person. Qualifications and
expected duties of the safety & health professional are outlined in Appendix P.
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6. ON SITE CONSTRUCTION SAFETY COMPETENT PERSON
(new)
All construction projects are required to have a construction safety competent person on
site during periods of active construction. This individual’s responsibilities include:
•
•
•
•
•
•
•
•
Lead the Daily Hazard Analysis (DHA) meeting at the beginning of the shift
Identify and correct unsafe conditions
Stop work if hazardous conditions are encountered
Revise the Activity Hazard Analyses and/or Daily Hazard Analysis where need
Complete the weekly construction safety checklist
Ensure all employees and subcontractors have completed the KCP ES&H site
safety orientation prior to starting work
Ensure all required ES&H permits are current and posted for the project
Review and have a working knowledge of the KCP Construction Safety Handbook
This individual will be identified in the seller’s project safety plan. The individual must
complete the OSHA 10 hour construction safety training program and hold the 10-hour
construction safety card at a minimum.
7. SAFETY PROGRAM ELEMENTS (updated)
The Seller has the responsibility to follow a general health & safety program, develop and
implement project specific health & safety plans that address unique hazards and
conditions related to their project. The Seller is the entity having overall responsibility and
control of the project. The Seller’s health & safety program must demonstrate the
elements identified below for maintaining safe working conditions and assuring safe work
practices for its employees. The Seller’s lower tier subcontractors shall operate within the
purview of the Seller’s Safety Program and Project Specific Safety Plan.
This must be a detailed plan covering the actual project you and your subcontractors will
be working on. Look at all phases of the job: demolition; remodeling and equipment
installation. After reviewing the project drawings and specifications, address what you will
be doing and how your workers will be protected.
No work can begin on the construction project until the safety plan is written and accepted
by KCP (See appendix A for elements to include). Your written safety plan is a
construction submittal and must be submitted as specified in construction specification
section division 1 general requirements, section # 01330, title submittal procedures. All of
your personnel and lower tier subcontractor personnel shall be briefed on the safety plan
and know where a copy is maintained. The plan must include the following:
A. Cover page
Include your company name, address, date, and project name and contract number as
well as a contact person.
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B. Qualification list
The Seller shall provide the name and qualifications (i.e., training, past experience,
education) of the jobsite management and the competent individual assigned
responsibility for administration of the safety and health program. A method of
contacting the representatives on-site shall be included.
C. Activity Hazard Analysis
This is the heart of your site-specific safety plan. This consists of the identification of
site hazards and controls, principal work steps, associated task hazards and controls,
necessary permits, and worker training. In other words, Integrated Safety Management
(ISM). ISM is a common sense approach to doing work safely. Treat safety as an
equal and essential part of the job, not as an add-on or after thought. All Seller and
lower tier subcontract personnel shall be briefed on the Seller’s project specific safety
plan and Activity Hazard Analysis prior to performing work. Copies of the AHA and
Project Specific Safety Plan will be maintained and available for review by all Seller and
lower tier sub-personnel. A copy of the approved AHA shall be posted at the project
site. The Seller shall update the Activity Hazard Analysis to address specific items of
work when new hazards are identified or when phasing of work benefits from later
receipt of supplemental work specific information. See appendices N and O.
D. Medical Care Provider (new)
Each seller shall identify their selected health care provider in the site specific safety
plan. The medical care provider will be responsible for evaluation and medical care of
the seller’s employees who will be working at the KCP. The seller shall also provide
pertinent information to their selected health care provider of hazardous materials their
employees are exposed to. This will ensure the sellers employees are covered in
medical monitoring programs. These include hazards requiring medical monitoring
under OSHA, for example, asbestos, lead, noise, or beryllium. (see section 16 for more
details on medical surveillance requirements)
E. Flow-Down Clause
All requirements of the safety program shall be included in the purchase orders as
flow-down clauses. The Seller’s lower-tier subcontractors must comply with the Seller’s
safety program and project specific safety plan.
F. Weekly Safety Meetings
The Seller’s project foreman, safety professional and/or competent person shall
conduct weekly safety meetings on-site, and maintain written attendance sheets
including safety topics discussed. Foreman shall provide copies of meeting attendance
and safety topic sheet to ES&H when requested.
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G. Hazardous Materials
Environmental restoration projects or other projects involving exposure to hazardous
materials shall include a site-specific determination of the levels of personnel
protection, decontamination area(s), emergency notification procedures, and method of
keeping unauthorized personnel off the site. If you will be involved in remediation sites
or deal with hazardous materials, you may be required to submit a safety plan which
addresses the impact of 29 CFR 1910.120.
H. Pollution Prevention
Include the following statement in your safety plan, "Consistent with the national policy,
pollution shall be prevented or reduced at the source wherever feasible." Describe the
activities you will undertake to meet this policy. This applies to all forms of pollution,
i.e., air emissions, water discharges, and solid waste.
I. Daily Hazard Analysis
Seller and lower-tier subcontract personnel shall be briefed daily on assigned work
tasks, associated hazards and their controls prior to commencing work (reference
appendix O). This briefing shall be documented and available on premises for the
duration of the project. Those workers failing to utilize appropriate protective measures
are subject to the warning ticket / citation process.
J. Demolition Activities
If the project requires the Seller to perform demolition activities, the Seller shall create a
section in the project specific safety plan that addresses demolition activities. The
demolition plan shall state the hazards expected to be encountered during the course
of normal demolition activities. Include what will be done to minimize the hazards
identified and protect the employee during demolition. Items to consider include lead
paint, electrical systems, plumbing, duct removal, steam systems and other energized
systems etc.
EXAMPLE: This project includes the demolition of electrical circuits. Hazards
normally encountered in electrical demolition include exposure to electrical energy.
To assure worker safety, only qualified electricians trained to recognize and
eliminate electrical hazards will be utilized to perform electrical demolition activities.
If the demolition plan utilizes laborers to perform electrical demolition, a plan to
assure the laborers safety shall be provided. – example: use of lo/to, marking the
lines to distinguish between energized and de-energized lines. Lines identified shall
be physically disconnected at both ends.
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8. SAFETY PROGRAM IMPLEMENTATION
To ensure your written safety plan is followed by both your employees and sub-tier
employees, the following must be included in the implementation of your written safety
plan.
A. Seller management leadership and employee participation in ES&H at KCP.
Seller’s program shall demonstrate that managers, supervisors, and employees are
provided with the authority to access relevant information, training and resources to
carry out their Environmental, Safety & Health responsibilities.
For projects that do not require a full-time Safety Professional on-site, the Seller shall
designate the on site competent person(s) who holds at a minimum the OSHA 10 hour
construction safety card to assume the role and responsibility of the safety
professional. The Seller’s safety professional shall be responsible for reviewing and
monitoring all potentially hazardous operations.
B. Hazard identification and assessment
Seller’s program shall document that frequent and regular inspections of the workplace,
materials, and equipment are made by competent persons designated by the employer.
Seller shall document the assessment of project hazards and identify hazard controls
for hazardous work elements prior to work start-up (Activity Hazard Analysis).
Seller shall evaluate and document daily work hazards, reviewing with employees prior
to beginning work each day (Daily Hazard Analysis).
C. New means and methods
We are always open to new means and methods. If you have knowledge of a safer or
new system for performing the job, let us know. We understand that tools, equipment
and techniques continue to improve. If you have a process that is not covered in this
handbook, let us know and we will evaluate your plan.
D. Hazard prevention and control at KCP
Document hazard controls for work elements (tasks) using an Activity Hazard Analysis
form (Appendix P) for work elements prior to work start-up. A project-specific Activity
Hazard Analysis (AHA) must be written and accepted by the Buyer prior to work being
performed. The AHA must include the following:
1. Sequential listing of the work elements (job tasks) within the project.
2. Potential hazards associated with each work element (job task).
3. Hazard controls for each hazard identified for work elements (job tasks).
Document daily work hazards using a Daily Hazard Analysis form (Appendix O or
similar) and review with employees prior to beginning work each day.
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E. Safety information and employee training/qualification
•
•
•
•
Review ES&H information with workers and subcontractors as required.
Workers shall be trained to minimum OSHA requirements.
Ensure each employee is adequately trained to perform assigned work.
Seller shall maintain a listing of training and qualification records of employees and
lower tier subs at the KCP.
F. Periodic evaluation of program effectiveness
•
Perform periodic evaluations of your construction safety program to ensure it is
effective and appropriate for workplace conditions.
9. SAFETY INSPECTIONS & MEETINGS
A. Facilities Engineering Inspections of the Construction Sites
The construction site will be inspected on a routine basis. Warning tickets and citations
will be issued through ES&H if health or safety violations are observed.
B. Inspections by NNSA/KCSO Personnel
The construction site may be inspected by a NNSA official at their discretion.
NNSA/KCSO officials may also inspect projects on a routine basis.
C. Inspections by Environment, Safety, and Health (ES&H)
All construction sites are subject to routine inspection by ES&H. Warning tickets and
citations will be issued if violations are observed. All ES&H violations will be routed
through the Construction Manager/Title III Engineer for corrective action by the Seller.
D. Seller Inspections and Reviews
Seller’s safety professional and or competent person shall make formal weekly
inspections of all Seller construction sites and activities. A construction safety checklist
self-inspection sheet is included in this handbook (See appendix B). All construction
contractors shall use this list to review their project sites. KCP’s ES&H will be auditing
your construction sites to this list. Other daily or routine inspections shall be
documented as required by OSHA Standards.
1. The Construction Manager/Title III Engineer shall be made aware of such
inspections and be invited to participate.
2. The Seller shall perform all corrective actions on all identified items in a timely
manner.
3. Monthly, the inspection/audit data from the construction safety checklist shall be
provided to the KCP Construction Safety Engineer.
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E. Monthly Superintendent Meetings
Monthly KCP’s Purchasing Department schedules safety meetings with all construction
contractors on-site at that time. All on-site management or lead persons are required
to attend. Your company will be required to present a safety topic to the group during
the superintendent safety meeting. If your company has had an accident or injury
during the period between meetings, you will be required to make a short presentation
on the accident, lessons learned and corrective actions taken. We encourage you to
take an active role in these meetings and share the information gained with coworkers.
10. WARNING TICKETS & CITATIONS
A. Warning Tickets
1. All minor violations will be documented by the Project Engineer or Safety
Engineer through the use of a warning ticket. These shall be used to determine
repeat violations by the Seller and/or lower-tier Seller. (See Appendix C)
(Non-serious violations that have a relationship to safety and health are those
that probably would not cause death or serious physical harm.)
REQUIREMENT: Three warnings in a 30-day time period for the same concern
shall result in the issuance of a citation.
2. Non-serious violations noted by KCP’s ES&H personnel or NNSA personnel
may result in the issuance of a warning ticket to the Seller.
3. You must correct the non-serious violation within one day. The Seller shall
contact the Safety Engineer for concurrence when action is completed.
B. Citations
Violations of OSHA 1926, Standards for the Construction Industry, any applicable parts
of the OSHA 1910, General Industry Standard, or this handbook will be documented on
the KCP’s Occupational Safety and Health Citation form. (See Appendix D.) Citations
will be issued when one of the following occurs:
1. A violation which could reasonably be expected to cause death, serious physical
harm, or extensive property/environmental damage if it is not stopped
immediately (citation);
2. A violation that the Seller intentionally and knowingly commits or is aware that a
hazardous condition existed and made no reasonable effort to eliminate it
(willful);
3. A violation of any standard, regulation, rule, or order where, upon re-inspection,
a substantially similar violation is found (repeated);
4. A violation where there is substantial probability that death or serious physical
harm could result and that the employer knew or should have known of the
hazard (serious). Seller shall correct citations immediately.
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5. Violations that could result in a citation noted by ES&H personnel will result in a
citation.
6. NNSA may issue citations through KCP at any time.
C. Contract Remedies
Buyer reserves the right to take any contract actions necessary for violation of the
safety requirements, including termination of the contract for default.
D. Sellers Disciplinary Process
All general contractors shall have a written disciplinary process for both their
employees and subcontractors who fail to utilize appropriate protective measures on
the job site.
E. Employee Expulsion Policy
Any contract employee who is removed from the Kansas City Plant for failure to follow
established ES&H or Security requirements may not be allowed to return to the KCP as
a contractor or under employment for another seller. Additionally, any contract
employee who does not meet performance expectations may not be allowed to return
to the KCP. Each individual case will be reviewed. Names of individuals that have
been removed will be tracked by the Security Department to deny entry to the facility.
This rule applies to the Seller’s employee who is removed from the plant by KCP’s or
the sellers’ management.
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11. REPORTING/POSTING REQUIREMENTS
A. Unforeseen Hazard Posting
Workers must be instructed to report to the project supervisor hazards not previously
identified or evaluated. If immediate corrective action is not possible or the hazard falls
outside of project scope, the project supervisor must immediately notify affected
workers, post appropriate warning signs, implement needed interim control measures,
and notify the project engineer of the action taken. The contractor must stop work in the
affected area until appropriate protective measures are established. Unforeseen
hazard signs are available from KCP ES&H if needed.
B. Accidents/Injuries/First aid cases
All construction and non-construction injuries which take place at the Kansas City Plant
shall be reported to the Safety Department immediately. KCP associates will assist
and provide you with the forms identified below.
DOE Form 5484.3, "Report of Occupational Injury/Illness," to be completed for each
reportable occupational injury or illness, as defined by OSHA, involving any
employees (See Appendix E).
C. Property Damage (updated)
All fires, property damage, accidents, or losses to government property must be
reported to the Project Engineer.
D. Tabulation of Work-Hours
All construction work-hours must be reported to the buyer monthly. Work-hours
must include both the general contractor and all subcontractors who worked on the
construction project. List work-hours and company names of each subcontractors.
This report shall be submitted to the KCP purchasing department monthly and will
be due on the first day of the next month. This form is available from the buyer.
E. Posting Requirements
The Occupational Safety and Health Protection Poster (F 5483.1 [12-93]) shall be
posted on all projects or work centers. The Seller shall assure that their personnel are
aware of their health and safety rights.
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F. Posted Construction Areas
All construction areas shall be posted appropriately by the construction general
contractor. All signs are available from ES&H.
The Seller shall:
•
Post “Remain Clear Of Construction Work” and project information sign as well
as any required permits at the main point of entry into each construction area.
•
Post “Construction Area Hard Hat & Safety Glasses Required” within the
construction work area.
•
Provide and place warning signs and barricades for the protection of
non-construction personnel. Construction area boundaries are to be identified
by rope, barrier tape, fencing, or other means. The area must be of sufficient
size to contain the hazard. Take into account the height of what is being
worked on. Adjust the size of the work area boundaries as necessary during
the project.
•
When performing work outside of the posted construction area (installing
equipment on the roof as part of a project below) install barricade tape around
the work area and attach a “Notice” tag to the barrier tape with project number
and contact person with telephone or pager number.
G. Emergency Evacuations, Reporting and Medical Care (updated)
1. When a siren/warbling tone is heard over the emergency notification system, it
indicates a plant emergency. All personnel shall leave the work area and wait
for further instructions.
2. If an emergency situation exists such as fire, injury, environmental damage, or
explosion, call 3600 for assistance. The individual reporting the incident shall
state his or her name, location, type of emergency, and location of the
emergency.
3. It is the responsibility of the Seller to direct the medical care of their employees
through their identified medical provider. The KCP Medical Care Services will
provide only emergency and stabilization care.
4. Contractor personnel shall participate in an annual emergency evacuation or
sheltering drill if they are on-site during the time and day of the drill. The drill will
last approximately 30 minutes, not to exceed one hour. The Seller will not be
reimbursed for participating in the drill.
H. Equipment Identification/Removal from the plant
Prior to the removal of materials, equipment, or tools through a perimeter security
inspection post, coordinate with the Project Engineer and obtain a 55A, Construction
Tools, Equipment, or Material Transfer Pass.
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12. PERMITS (updated)
A. Types
Various work permits and forms are required for construction and construction-related
service activities such as:
•
•
•
•
•
•
•
•
•
•
•
Penetration Checklist
Utility Location and Excavation Permit
Hot Work Permit
Life Safety Aisle/Exit Impairment Permit
Confined Space Entry Permit
High Hazard Construction Safe Work Permit
Permit for Energized Electrical Safety (PEET)
Drain Connection / New Discharge Approved Form
Fire Protection System Impairment
High Voltage Pre-Job Safety Checklist / Electrical Shutdown
Utilities Permit for Modification
The Seller shall initiate all permits required to perform work at the Kansas City Plant
and identify permitting requirements in the Project Specific Safety Plan/Activity Hazard
Analysis (AHA) and Daily Hazard Analysis (DHA). The Seller shall complete required
permits and obtain all signatures prior to proceeding with construction work. All permits
shall be up to date and posted at the jobsite.
Hot Work Permits are issued by the KCP Fire Department. High Hazard Construction
Safe Work Permits, Aisle Impairment Permits, and Utility Location & Excavation
Permits are issued by Construction Management Associates. Many of these permits
require advanced notice and coordination prior to work.
B. High Hazard Construction Safe Work Permits
High Hazard Construction Safe Work Permits are issued for non-routine high hazard
operations such as but not limited to:
•
•
•
•
•
•
•
•
•
Scaffold work (any height)
Steel Erection
Use of Cranes
Helicopter Lifts
Shoring
Critical / Unusual lifts
Concrete Masonry Wall Installation (> 8ft)
High Voltage Work (Over 600V)
Removal of roofing materials and /or the removal/installation of items that
penetrate the KCP roof.
Permits may be issued on a daily, weekly, or monthly basis. Completion of this form
requires participation of contractors with ES&H, Project Engineer and area owner.
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C. Utility Location & Excavation Permit
The Utility Location & Excavation permit shall be completed any time construction
activity disturbs soil/sub grade, including penetrations through
slabs/floors/concrete/asphalt where the soil/sub grade will be disturbed.
Examples include internal or external excavation, trenching, soil borings, ground rod
installations, or any other construction activity that has the potential to disturb a buried
or encased utility in the soil.
Requesting a permit: Minimum 3-day advanced notice is required to adequately
research and identify hazards that may exist at the excavation site.
These permits are generally issued on a daily or weekly basis depending on the
operation. Permits may be issued for any period that is decided appropriate by the
Project Engineer. Excavations should be reviewed prior to entry and the permits
reviewed weekly as a minimum. Advanced notification is required to allow Buyer to
perform a basic review of potential utilities in the area. Seller is responsible for
performing work in a manner that recognizes utilities may exist that are not identified by
the Buyer’s utility locating equipment (See Appendix R).
Note: For areas outside the perimeter security fence Missouri One Call shall be
contacted for utility locations (1-800-DIG RITE)
D. Penetration Checklist (new)
The penetration checklist replaces the class 2 penetration permit. The new checklist
allows the contractor to locate utilities and re-bar themselves in concrete 4 inches or
less in depth. The checklist shall be completed prior to any saw cutting, jack
hammering, drilling or penetration of asphalt, concrete ceilings, floors, columns, beams,
roof ribs, concrete & metal roofs, footings, foundations, exterior slab on grade (concrete
& asphalt) or suspended slabs (ramps, etc.) (See section 19 and Appendix Q.)
Exemption - Work under construction the Seller has installed as a part of the same
project does not require a penetration permit.
E. Life Safety Aisle/Exit Impairment Permits
Life Safety Aisle/Exit Impairment Permits are issued for tasks that will require the aisle
to be partially or totally blocked for a period of time. If an aisle must have on-going
work, then a permit will be issued to identify the work and materials that will be within
the life safety lines. Basically no more than one half of the aisle (minimum of 36”) may
be blocked for a partial and the partial impairment must last two hours to require
permitting. Total blockages require a 24-hour notice, considerable coordination and
are generally permitted only on off-shift to keep the risk levels lower. Remember, if you
block less than half the aisle for less than 2 hours, you do not need a permit.
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F. Utility System Modification Permit
Utility system modification permit is required for all utility modifications, including those
that install or remove equipment. The Seller/CM/Planner shall file a permit with the
designated Utility Engineer prior to construction. The permit shall identify the system,
location of work, type of work and estimated duration of the work. The Utility Engineer
shall review and return the request for approval within 3 working days. The permit shall
reside with the seller until the work is completed and post-installation testing is
performed. The Utility Engineer has the option to witness post-installation testing with
24-hour advance notice (See appendix S).
G. Revocation of Permits
Permits may be revoked for noncompliance violations. Upon revocation of the permit,
the Seller shall submit in writing to the Project Engineer the corrective action that will be
taken and action taken to prevent recurrence. If corrective action is acceptable,
another permit will be issued. Revocation of a permit will result in the issuance of a
citation.
13. ENVIRONMENTAL PROTECTION
The Kansas City Plant has achieved ISO 14001 certification, The Environmental Management
System Standard. With your help, we can maintain our ISO status and be one of the most
environmentally friendly facilities in the DOE community.
A. Excavation Concerns
Due to possible soil contamination, excavation work shall be initiated only after a Utility
Location & Excavation Permit is issued. Excavated soils and wastewater policies shall
be complied with.
B. Hazardous Waste
The disposition of all wastes must be addressed in the project specifications. For
situations that are not addressed in the specifications, the Project Engineer shall
coordinate with KCP’s Waste Management Department to resolve the discrepancy.
C. Equipment/Tools Decontamination
Some demolition, equipment relocation and excavation projects have the potential to
contaminate work tools and machinery. Contractors working in areas where
contamination is known to be present must include in their safety plan a
decontamination plan of equipment, including fork-trucks, skid steers, hand tools, etc.
prior to removing them from the NNSA complex. Consider the use of cheap,
expendable tools as an option to cleaning. Some of the common contaminants include
PCB oils and solvents. Should your project include this type of work, disposal and
cleaning will be coordinated with KCP’s Waste Management Department.
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D. Asbestos Abatement
If you suspect asbestos on your work site, stop work and contact the Project Engineer
immediately. No asbestos removal or abatement work shall be performed by your
employees. Should you find any asbestos pipe insulation on the floor, contact the SPIL
hotline at extension 7745 to coordinate clean-up.
E. Decontamination
Water, steam, or other materials used to clean areas or equipment that may be
contaminated with toxic or hazardous substances shall be contained. Disposal of all
materials used shall be addressed in the project specifications or the buyer’s safety
plan.
F. Discharge to Drain Systems
No construction materials, wastes, spills, or leaks, including oil, cleaning solvents,
acids, caustics, coolants, concrete, mortar, gravel, sand, or fuel oil, shall be discharged
to any storm sewer drain. No material shall be discharged to any sanitary or industrial
sewer unless directed by the project specifications. Where discharge is anticipated as
a part of a process, contractor shall provide containment systems to protect drains.
Only rain event run-off may be discharged to storm sewers. Repeated or willful
noncompliance to this requirement shall be sufficient reason for termination.
G. Storage of Hazardous Waste
All storage of hazardous wastes (such as chemicals, toxic metals, asbestos) shall be in
accordance with the requirements of the project specifications. Contractor shall
coordinate with project engineer and ES&H regarding storage of hazardous wastes not
defined in the project specifications.
H. Disposal of Hazardous Waste
Hazardous waste containers are ordered for waste from each jobsite individually.
Containers with the labels shown below have STRICT RULES for use and return. Your
employees and subcontractors who work on a project where hazardous waste
containers are used must be aware of the following:
30
•
Containers labeled or stenciled can only contain that type of waste.
•
Do NOT move containers to another job, use anyone else’s containers, or
abandon them when the job is over.
•
All containers must be covered and barrel rings secured when not in use.
•
Fill out the end fill date when the container use is complete.
I. Spills and Leaks
Spills or leaks of any construction materials including oil, fuel, solvents, paint, coolants,
acids, caustics, equipment leaks, overflows, toxic solids, asbestos or any other
construction materials, must be reported immediately to Waste Management through
the SPIL Hotline, extension 7745, and the Project Engineer.
SPIL HOTLINE 7745 (SPIL)
SPILL: Any spilling, leaking, pumping, pouring, emitting, emptying, discharging,
escaping, leaching, dumping, or disposing of a chemical into the environment.
J. Environmental Control
Spills or leaks caused by faulty equipment or gross negligence of the Seller shall be
determined by ES&H and the Project Engineer. This can be sufficient reason for job
termination. To the extent possible, equipment leaks are not allowed. If a discernible
equipment leak is identified, the project engineer may advise ES&H and identify
mitigating actions to control the leak up to and including removal of the equipment from
the site. Equipment found by the Project Engineer to be in need of repair to prevent
spills shall be taken out of service and repaired at no added cost to Buyer.
K. Dust Control
Dust generated by construction operations shall be controlled by water or other means
acceptable to the Project Engineer, Buyer or ES&H.
L. Visible Emissions
Visible emissions, with the exception of water vapor from equipment vehicles, should
be avoided.
M. Prevention Guidelines
Prevent pollution at the source and use less toxic materials wherever feasible. This
applies to air emissions, water discharges, and solid waste generated.
N. Transport of Equipment
Prior to transporting operational equipment, drain, plug, and tag it with the appropriate
label or tag.
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14. LIFE SAFETY ON CONSTRUCTION SITES
Every construction site shall have at least two exits. If two exit routes are not available,
contact the KCP Fire Department for job site review. These exits and access routes to
them shall be adequately lighted, including emergency lighting, and be adequately marked.
The location of exits, number of exits, provision for normal and emergency lighting, and
marking of exits shall be reviewed by a fire protection engineer at the beginning of
construction and whenever the course of construction requires a change to the site layout.
Changes can occur because of security, safety, or construction progress. The installation
of dust curtains and partitions can adversely affect life safety. Any door designated as an
exit shall not be locked at any time. Fire Protection systems shall be maintained in service
as approved by the fire protection engineer. This often involves temporary wiring until
permanent circuits are installed. Requests for review should be made through the
construction manager or planner.
15. FIRE PROTECTION
A. Fire Protection Equipment
Fire alarm panels, fire hose reels, fire extinguishers, sprinklers, alarm systems, or other
fire protection equipment shall not be blocked, removed, or disconnected without the
approval of the KCP Fire Protection Department.
At the KCP, fixed fire protection systems, to include fire sprinkler systems, alarm
systems, smoke and heat ventilation systems, fire doors, fire dampers, Halon systems,
carbon dioxide systems, dry chemical systems, wet chemical systems, fire pumps, and
water supply valves shall be shut down or placed in service by Fire Protection
Department associates only. Requests for the Fire Protection Impairment (E-2742)
shall be made through the Project Engineer 24 hours prior to the planned shutdown or
impairment.
B. Aisle Blockage
All egress aisles, fire lanes, emergency exit doors, etc., shall remain clear and
functional for emergency use.
If activities necessitate blocking egress aisles, fire lanes, fire exits, and doorways, a
Life Safety Aisle/Exit Impairment Permit (E-2812) request must be submitted to the
project engineer a minimum of three days in advance for Fire Protection Department
review and approval. A partial obstruction for less than two hours does not require the
permit. A complete aisle blockage is generally not permitted during regular occupied
hours.
C. Fire Rated Walls
Activities that impair fire rated walls shall be coordinated with sprinkler work so that
both are not simultaneously out of service. Requests for impairing fire walls shall be
made through the project engineer at least 24 hours prior to the planned impairment.
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D. Internal Combustion and Propane-Powered Vehicles and Equipment
Propane-powered vehicles and propane-powered equipment shall comply with NFPA
58, NFPA 505, and be approved by the Project Engineer and Fire Protection
Engineering prior to using on-site.
1. Gasoline and diesel fueled vehicles and equipment shall not be permitted in or
on buildings, except where permitted by the Project Engineer, Fire Protection and
ES&H. When a diesel or LP powered industrial tool is needed, the following
requirements shall apply:
a) All diesel-powered equipment operated inside the facility must be equipped
with a properly operating scrubber/purification system or be directly
connected to an exhaust extraction system.
b) All diesel-powered equipment should be removed from the building when not
in use. If the equipment must remain in the facility, contact the Fire
Department for approval.
c) Routing of the exhaust must be reviewed and accepted by the Project
Engineer. If an exhaust system must be installed, the installation and
removal of the system is the responsibility of the Seller. Existing systems
may be used with acceptance of the Project Engineer.
d) Refueling activities shall be approved by the KCP Fire Protection
Department. Any equipment to be refueled on the roof must be done with
the Fire Department present.
e) During equipment operation, the work area shall be monitored for carbon
monoxide, explosive vapors, and oxygen levels as a minimum. Any elevated
levels will require the equipment to be shut down and the area ventilated
before work can resume.
2. Gasoline and diesel powered vehicles and other equipment not in use shall not
be left within the buildings.
3. Liquefied petroleum gas shall not be stored within any building or on any roof at
the Kansas City Plant.
4. Gasoline and diesel engines shall be refueled outside of buildings unless
otherwise specifically permitted in writing by the KCP Fire Department. LP gas
containers shall be changed outside of the building when possible.
33
E. Flammable Liquid Storage and Use
1. Storage of flammable liquids inside the buildings of the KCP must comply with
NFPA 30 and the requirements listed below. Flammable Liquid Storage Cabinet
Location Guidelines, Flammable liquid cabinet placement shall reflect the following:
a) Boundary areas a minimum of 5 feet from the edge of each side and 3 feet
from top of the opening of the cabinet and free of ordinary combustibles.
b) NOTE: Walls may reduce the dimensions on the sides and top of the cabinet
by altering the flammable liquid vapor path to travel. Vapor travel distance to
ignition source shall not be less than noted above.
c) A maximum of three (3) flammable liquid storage cabinets adjacent to each
other (the boundary is applicable to the ends of the outer 2 cabinets and the
fronts and backs of the cabinets).
d) A minimum of 100 feet separation between groups of cabinets within the
same fire area.
e) NOTE: Flammable liquid storage rooms are exempted from the total cabinet
limit, and are limited by design capacity requirements.
f) The maximum number of cabinets within a 2-hour fire rated area shall not
exceed a storage capacity of 600 gallons, unless additional minimum 1-hour
fire rated separation is provided.
g) Be separated by a noncombustible wall or located 5 feet or more from any
aisle that is used for emergency egress unless written approval is given by
Fire Protection Department. A copy of the written approval shall be
conspicuously displayed on the cabinet or within the boundaries for the
cabinet.
h) Be easily accessible for firefighting operations.
i) Provide a minimum of a 40B:C rated portable fire extinguisher located within
30 feet of the storage area.
34
2. Flammable Liquid Storage Cabinet Storage guidelines:
a) Store only closed containers one tier high per shelf within the cabinet, not to
exceed 15 gallons per shelf.
b) Store quantities less than or equal to the rating / listing of the cabinet.
c) Store all flammable liquids within the cabinet [(hazard of 3 or 4 in the fire
quadrant of the NFPA diamond or HMIS square (MSDS) material storage
class (A)].
d) Combustible liquids may be, but are not required to be stored within the
cabinet [(rated hazard of 1 or 2 in the fire quadrant of the NFPA diamond or
HMIS square (MSDS) material storage class (B)].
e) Combustible liquids shall not displace or supersede requirements for
flammable liquids to be in the cabinet.
f) Flammable aerosols shall be stored in a flammable liquid cabinet.
g) Flammable liquids which are not used in daily operations shall be stored in
approved containers within the cabinet, or shall be removed from the KCP.
h) Combustible materials, such as empty cardboard boxes, paper, wood, tote
boxes, and rags shall not be stored in flammable liquids cabinets.
i) NOTE: Special cases allowed in the cabinets are multi-part kits, large
quantities of small size containers (tubes of glue and collapsible containers).
j) Store any flammable liquid not in use during the shift in an approved
flammable liquid cabinet. This includes aerosol spray cans, red plastic
squeeze bottles, flammable liquid safety cans, and dip cans.
k) Do not store other materials in the cabinet.
3. Storage Outside of Buildings
Storage of flammable liquids outside of the buildings of the KCP must comply
with NFPA 30 and the requirements listed below:
Container storage (five gallon containers and less)
a) Containers must be:
(1) NRTL (UL/FM) approved metal Safety Cans
(2) Have self-closing (spring) lids and flash arrestor screens
(3) Maximum sized container allowed is five gallons.
b) Quantities:
35
•
Quantity limited to amount needed for efficient operations (2-day
supply) not to exceed 25 gallons (five 5-gallon containers).
c) Storage location:
(1) No storage inside office trailers, material storage trailers, or on the
roof.
(2) Maintain separation distances from important combustible
buildings and or materials of not less than fifty (50) feet.
(3) Maintain separation distances from important noncombustible
storage or solid masonry walls with no penetrations of not less than
twenty-five (25) feet.
(4) Important buildings would be considered any NNSA-owned
buildings, buildings with high value or mission critical functions, and
buildings not owned or operated by/for the KCP. (Construction trailers
would not be considered an important building.)
(5) Outside storage must be protected from weather, theft, and
provide spill containment (i.e., a watertight, leak-proof job box or
flammable liquid cabinet secured such that wind will not tip over the
box/cabinet).
(6) Flammable cabinet or box shall be clearly labeled "Flammable Keep Fire Away" and contain the NFPA Diamond label (Gasoline is 13-0) on all four sides.
(7) Flammable/combustible liquids must be separated from flammable
gas (LP, acetylene, etc.) and oxygen cylinders by at least 20 feet.
(8) Storage location must not impede or present a danger to any
building exit route, including exits from construction trailers.
(9) Area surrounding flammable storage areas shall be kept clear of all
trash, debris, weeds, and other combustible material.
(10) Storage location must be easily accessible for fire fighting
operations.
(11) Provide a minimum of a 40B:C portable fire extinguisher located
within 30 feet of the storage area.
(12) Portable extinguisher shall be inspected and maintained per
NFPA 10 Portable Fire Extinguishers.
36
(13) For outside storage in containers larger than 5 gallon (drums, portable
tanks, etc.) containers or quantities exceeding 25 gallons, please contact
KCP Fire Protection and Environmental Operations Departments for required
guidance.
4. Using Flammable Liquids
a) Refueling operations shall be conducted outside in an area that is safe to
dispense flammable liquids.
b) Report spills promptly to Environmental Operations at extension 7745 or dial
SPIL.
c) Contact Fire Protection Department prior to taking flammable liquids onto the
roof. A FPD escort is required for all flammable liquid operations on the roof.
d) Contractor personnel must be trained on the appropriate use and hazards of
the flammable liquid.
F. Hot Work (Welding, Cutting, Grinding, or Spark-Producing Activities)
1. Hot Work Permits shall be required for each shift.
2. Where hot work operations are to be performed, a Hot Work Permit shall be
obtained from the Fire Protection Department (extension 3711). Permits shall be
required for each hot work job performed on the site.
3. A Hot Work Permit can be obtained by calling the Fire Protection Department
(X3711). The name of the requester and company performing the work, location of
work, and type of work to be performed shall be required when requesting a Hot
Work Permit.
4. Any painting or solvent activities must be at least 40 feet from any hot work.
5. Ensure the proposed hot work site is free of flammable or combustible materials.
6. Work that includes use of portable power saws and grinders on metal or
spark-producing surfaces shall require a Hot Work Permit.
7. All welding shall be shielded to protect personnel from rays, sparks, and slag.
Fire blankets shall be used to protect flammables and combustibles from sparks
and slag.
8. Hot work shall not be performed on ducts, plenum chambers, and dust-collecting
systems until the units have been shut down, the duct cleaned, and all combustible
lining and covering materials removed from that portion of the duct being cut or
welded. Approval from the Project Engineer must also be received.
37
9. Special precautions for overhead work and wall or floor penetration will be
outlined by the issuing Buyer's Fire Protection representative prior to commencing
work.
10. A dedicated fire watch, whose duties are solely to watch the person performing
the hot work and the immediate surrounding area to ensure the person’s clothing or
surrounding materials do not catch on fire, shall be required and is to be provided
by the Seller for each person conducting hot work. A second or third fire watch may
be required by authorities issuing the permit if sparks or slag could fall into areas
not seen by one fire watcher. Both the hot-worker and fire watch shall be available
to sign the hot work permit.
11. Hot work within confined spaces shall require both a Hot Work and Confined
Space Entry Permit.
12. No Hot Work Permit will be issued in areas where sprinkler systems are
impaired.
13. The issuing or reviewing Fireman has the authority to suspend or revoke the
permit if conditions are not met or conditions change which could be considered
hazardous.
14. Ensure that personnel are properly trained to perform work requiring a hot wok
permit.
15. Individuals involved in hot work operations shall have fire extinguisher training
provided by their employer.
16. Failure to maintain the precautions outlined below shall automatically invalidate
the Hot Work Permit.
a. Welding equipment shall be in good repair.
(1) Both oxygen and acetylene systems shall have back flow check
valves and flame arrestors at the regulator and the torch body.
(2) All cylinders transported on or by a powered vehicle shall be
secured in a vertical position.
(3) All oxy-acetylene hoses and tips shall be removed from vessels
during breaks, lunch times, and at the end of the day.
(4) All oxy-acetylene gages shall be removed from the bottles at the
end of each shift and stored with protective caps secured.
b. Combustible floors shall be wetted down or covered.
c. Combustible material within 35 feet of work to be performed shall be
relocated or covered with approved fire blankets.
d. Flammable liquids within 35 feet of work to be performed shall be
relocated.
38
e. Wall and floor openings within 35 feet shall be protected from the hot
work being performed.
f. Fire blankets shall be suspended beneath overhead work to catch sparks
and slag where reasonable potential for fire or injury to personnel exists.
g. Sight barriers shall be provided by the Seller to protect others from
glare/flash of arc.
17. Roof Work With Hot Tar
a. No flame torch applied roofing or drying will be allowed at the KCP.
b. A Hot Work Permit shall be obtained from the Fire Protection Department
prior to firing up roofing tar pots. While the tar pots are being fired, the Seller
shall furnish a fire watch whose sole duty is to stand watch over the pot.
c. The Seller shall supply at least two 20BC fire extinguishers at the tar pot.
d. Tar pots shall be located at least 20 feet from a building and shall not
block any exits from a building.
e. The fire watch shall be knowledgeable of the kettle’s operation and
appropriate safety responses. Stay within 25 feet of the operating kettle, and
keep the kettle within sight at all times.
f. The LPG cylinder(s) for the tar kettle shall be secured to prevent
accidental tip over.
g. The tar kettle shall have doors permanently attached.
h. The tar kettle shall have a working and visible temperature gage that
indicates the temperature of the material being heated.
i. The tar kettle temperature shall be kept at least 25°F below the flashpoint
of the tar being used. (In general, max temp is not more than 500°F)
G. Portable Heaters
Use of portable heaters is allowed only if they are NRTL listed and prior permission is
obtained from the KCP Fire Protection Department.
39
H. Housekeeping
Housekeeping practices shall include, at a minimum, daily disposal of construction site
wastes and empty containers originally containing flammable or combustible contents.
During work on the roof, all materials shall be secured at all times to prevent their
blowing across the roof. At the end of the workday all scrap and trash shall be
removed from the roof and project site. If the Seller fails to remove trash and scrap
materials, the Project Engineer may cause such cleaning to be done by the Buyer or
others and charge the cost to the Seller.
Housekeeping shall be considered a part of each job procedure. All areas shall be kept
clean. Materials and equipment shall be placed and stored in orderly fashion in an
area designated by the Project Engineer.
I. Storage of Combustible Materials
Storage of combustible materials is not allowed in building areas without automatic
sprinkler protection. Storage areas shall not block or obstruct exits or access to Fire
Department equipment or utilities shutoff controls.
J. Smoking Policy
Smoking is allowed only in the outside smoking shelters. Smoking shelters are located
as follows:
•
•
•
•
•
West of the employment lobby entrance
North of the east door to the MSB
North by shipping and receiving
North of the east power house cooling towers
West power house garage area
Two time periods on each shift have been set aside for smoking. Exceptions to these
designated times may be made by your Project Engineer for those contractors whose
job duties preclude the following schedule.
First Shift
Second Shift
Third Shift
9 a.m. to 10 a.m. & 1 p.m. to 2 p.m.
5:30 p.m. to 6 p.m. & 9:30 p.m. to 10 p.m.
1 a.m. to 1:30 a.m. & 4:30 a.m. to 5 a.m.
The consequences for failure to follow the smoking policy range from five days
suspension to termination from working at the KCP.
Note: Smoking is allowed at any time outside of the KCP fence. Please remain 50 feet
away from the entrances. Smoking is not permitted inside any building or construction
trailer.
40
16. INDUSTRIAL HYGIENE & HEALTH PHYSICS
The Kansas City Plant (KCP) is committed to providing a safe and healthy work
environment for its employees as well as subcontractors. The safety and health of workers
is a top priority. Honeywell, FM&T has committed considerable resources and efforts to
make the work environment as safe as possible. Safety and health inspections are
conducted on a regular basis as well as monitoring for airborne contaminants and other
potential health concerns. Rules and policies have been developed and must be followed
to ensure a healthy work environment. Therefore, it is important contractors become
familiar with the rules and policies regarding safety and health while working at The
Kansas City Plant.
A. Hazardous Material Sampling
Subcontractors are encouraged to notify KCP’s safety and health department of
concerns and issues they may have. KCP will address concerns and provide any
available information regarding specific safety and health concerns. If a subcontractor
feels additional steps are needed, they may, at their own discretion and expense, take
additional steps to ensure the safety and health of their workers, such as performing air
monitoring on their workers. Contact the KCP’s Industrial Hygienists for assistance
before performing any sampling.
B. Employee Protection Systems
Do not block, make inoperable, remove, or disconnect exhaust systems, emergency
eyewash/shower units, or breathing apparatus equipment without approval of the
Project Engineer.
NOTE: Any inadvertent impairment of these systems shall be brought to the immediate
attention of the Project Engineer.
C. Ventilation and Dust Control
1. Exhaust ventilation is required in conditions where fumes or vapors of paints,
sealants, or exhaust fumes pose a potential health risk to employees working in the
area or adjacent areas. This also includes the use of propane or internal
combustion equipment inside the plant that may generate exhaust fumes. (Exhaust
fumes must be properly ventilated to the outside.)
2. Particulate dust control shall be performed by a method acceptable to the
Project Engineer. Wet removal methods or sealing of the area may be required to
isolate dust from occupied areas.
3. When working around exhaust stack or ducts at vapor level, use Lockout Tagout
(LOTO) to prevent exposure.
41
4. Breaking, grinding, or sawing of concrete or other dust-generating materials
within the building requires dust and silica control measures. The use of water fog,
mists, or other effective means approved by the Project Engineer is permissible.
Dust from these activities shall not be allowed to enter the factory ventilation
systems. Failure to comply with this requirement will result in the issuance of a stop
work order. Seller shall be liable for damage to machines, parts, and equipment
caused by violation of this section. Seller shall also be required to clean all areas
contaminated with concrete or other construction-related dust.
D. Painting / Coating Application Guidelines
The purpose of this guidance is to provide basic framework to use when painting at the
KCP. The most important element is to communicate early in the planning process
with affected departments/associates in the immediate and surrounding areas. Contact
area owners in the affected departments to describe the work to be done, materials to
be used (including MSDS), and timing of when the work needs to be completed.
1. Determine the optimum time this work can be accomplished to minimize the
impact on normal operations and creating additional costs.
2. Less-toxic paints must be used in place of more-toxic paints when available. For
example, alternatives must be investigated for paints containing carcinogens. If
paints containing carcinogens must be used, they must be used in accordance
with a KCP’s Carcinogen Control Safety Plan.
3. Nonflammable paints must be used in place of flammables when available.
4. Paints containing high solvents (>3.5 lbs./gallon VOC), toxic or irritating odors,
and covering large occupied areas or areas sharing HVAC systems with
occupied adjacent spaces, should be applied when normal operations can be
temporarily halted until paint cures and odors dissipate (typically on second or
third shift or on weekends).
5. When irritating paints or paints with high, objectionable odors (though the paint
is not particularly toxic) are to be applied in an area occupied by associates in
close proximity to the area to be painted, it should be given consideration
whether paint is to be applied on second or third shift or on weekends. Latex or
other water-based paints are not considered to fall into this category.
6. Paints (such as safety yellow) applied to small areas (such as near fire
equipment) may be applied on first shift (provided it is to cover only small areas
and is in large, open areas such as aisles) when not in closed areas occupied by
associates.
42
7. All paints must be applied with adequate ventilation or respiratory protection for
the painter. When large areas are to be painted, increased ventilation and
increased make-up air to the area is to be provided, where possible. (Additional
ventilation is not possible in some areas due to limitations of HVAC systems and
access to other sources of fresh air, or potential for freezing coils in the winter.)
8. Paints must be applied with brush, roller, or non-aerosol spray delivery systems
to minimize aerosols; very small areas (less than 8 ft. x 8 ft.) may be painted
using spray only when provisions are made to provide exhaust ventilation or
ES&H is consulted to provide other means to minimize exposure during spray
application.
E. Noise
1. Hearing Protection is mandatory for the Construction Contractor's personnel if
they are exposed to noise levels which exceed the requirements of 29 CFR
1910.95 which is an 8-hour time weighted average of 90 decibels (A-scale.)
Noise exposure that exceeds an 8-hour time weighted average of 85 decibels
(A-scale) will require the seller to provide a Hearing Conservation Program for
their affected employees. Hearing protection is required for the Contractor's
personnel in any area of the facility so posted. Construction sites requiring
hearing protection shall be posted.
2. Activities producing excessive noise (over 80 decibels) that impede normal
activity in adjacent areas must be conducted with the least impact to operations.
Coordination with the affected area owner will be necessary to determine the
optimum time this work can be accomplished to minimize additional costs. This
may require construction/demolition activities to be conducted on 2nd or 3rd shift
or on weekends.
3. No vibratory equipment (such as jack hammers) shall be used in any office area
during normal daytime working hours. This shall include the walls, ceilings, or
floors adjacent to an office area. Exception is allowed only with permission from
the Project Engineer and department supervision.
F. Asbestos-Containing Material
If you suspect asbestos is on your job site but it is not identified, immediately halt work
and contact the Project Engineer. If asbestos is present, the Project Engineer shall
make arrangements for asbestos removal.
G. Non-Ionizing and Ionizing Radiation
The use of lasers or ionizing radiation generating equipment will require notification to
the KCP’s ES&H Department prior to use.
43
H. Hazard Communication
All construction contractors will have a written Hazard Communication program on site
in compliance with 29 CFR 1926.59 and include Material Safety Data Sheets (MSDS)
for all hazardous materials used in support of the contract work. KCP will provide your
employees with MSDSs for materials as requested.
I. Confined Space Entry
1. The Seller is fully responsible for monitoring the atmospheric conditions in
confined spaces and verifying personnel entering the confined space are
appropriately trained.
2. Failure to have adequately trained personnel will stop the confined space entry.
3. All employees of the Seller who will be working in confined spaces must
complete Honeywell’s confined space entry overview course.
4. The group entering the confined space shall request authorization to enter a
confined space from KCP’s ES&H Department and fill out the confines space
entry form E2760. This request shall be made 24 hours in advance of the
proposed entry to ensure the Fire Department has a sufficient number of
associates on duty.
5. The confined space entry permit E2760 can be replaced with the sellers permit if
it is deemed adequate and it is determined to meet the requirements outlined in
the KCP confined space permit. The seller shall submit their permit as part of
the written safety plan for evaluation prior to start of the project.
6. An estimate must be provided of how long the confined space will be occupied.
7. A fire frequency radio supplied by KCP is required to be on-site during confined
space entry. The radios will be issued by the Fire Department on a daily basis
and must be returned to the Fire Department at the end of the shift.
8. The contractor must wear the appropriate personal protective equipment where
required.
9. Tripod- All confined space entries from vertical type permit spaces require a
mechanical retrieval system to facilitate non-entry rescue. The retrieval system
shall meet the requirements of 29 CFR 1910.146 (k)(3)(i)
10. The Contractor Confined Space Entry Permit shall be posted during the confined
space entry. Once completed, return the confined space entry permit to the KCP
safety department. The permit shall remain posted until the confined space
entry is terminated.
11. Post entry debrief – Mark the confined space entry form with any hazards
confronted or created in the confined space during the entry.
44
J. Hazardous Material Labeling Requirements
1. The Seller shall:
a. Ensure that all chemicals and hazardous materials are identified with a
hazardous material warning labels by the manufacturer prior to storage or
use.
b. Ensure that your employees understand the information on the warning
label.
c. Properly label the container with a replacement label containing identical
information if either of the following occurs:
•
The label falls off or is removed.
•
The contents are transferred to a new container for either moving or
storing.
d. Submit an inventory of all hazardous materials for your project to the
Project Engineer. The inventory shall be updated as materials are delivered
to or stored on site. The hazardous material inventory shall include the
Project Number, Material Name, Manufacturer, and the quantity of the
material.
K. Lead
Lead paint has been identified in the Kansas City Plant. Prior to initiating work, review
requirements of CFR 1926.62 and assure requirements are complied with. Contact the
ES&H Department to have painted surfaces tested for lead.
45
L. Beryllium Awareness
Beryllium is a naturally occurring metal used in aerospace, nuclear, electronics,
automotive, and other industries. Though useful, it may cause serious health problems
to those who are exposed to airborne particles. The most common health problem is a
respiratory disease known as Chronic Beryllium Disease, or CBD. Beryllium alloys
have been used in operations and are known to be present at the Kansas City Plant.
Some of the processes involving beryllium alloys caused contamination of work
surfaces and other building surfaces. Thousands of samples throughout the plant have
been collected to characterize the facility for beryllium contamination. Some areas of
the plant have been identified as containing elevated levels of contamination. While
most of these areas have had the contamination removed, some areas have yet to be
cleaned. These areas are posted and are administratively controlled. Do not enter a
posted area unless you are authorized and you have the chemical protective clothing
and equipment required to enter the area. Trace amounts of beryllium may be present
in dust and dirt on structural and equipment surfaces, especially elevated horizontal
surfaces. Any operation which may disturb beryllium-containing or suspected
beryllium-containing materials presents the potential for exposure to beryllium for the
Contractor's employees and KCP associates.
Exposure to beryllium can result in toxic effects which depend upon the concentration
level and duration of exposure. The Department of Energy has provided mandatory
employee protective measures for working with or around beryllium, beryllium alloys,
and beryllium compounds. Airborne beryllium is a respiratory hazard. Inhalation of
microscopic, beryllium-containing particles into your lungs may lead to three health
problems:
•
Acute beryllium disease,
•
Lung cancer, or
•
Chronic Beryllium Disease (CBD).
While beryllium is considered a human carcinogen, studies which show it can cause
lung cancer involve exposure to much higher levels of beryllium than anticipated at the
KCP (or allowed by OSHA and DOE). This is also true of the acute form of beryllium
disease. So, CBD is the chief concern with beryllium exposure. Also, some people
become sensitized to beryllium upon exposure. This means that the person’s immune
system has been activated. This seems to put the person at greater risk of developing
CBD.
M. Beryllium Training
All workers coming on-site will receive beryllium safety awareness training as part of
the safety and security orientation.
46
N. Beryllium Tools
In a continuing effort to remove unnecessary beryllium-containing items at the KCP all
contractors are to remove beryllium alloy non-sparking tools. Due to the range of
applications for non-sparking tools, the KCP is alerting its associates and contractors to
this potential concern. These tools are typically used around flammable gases and
flammable liquids. They can include hammers, sockets, bung wrenches, and open-end
wrenches (some are marked with becu, beco, or belco), etc. If you need assistance in
identifying these tools or have any other questions, feel free to contact extension 4040.
O. Subcontractor Beryllium Workers
Subcontractors who perform work that creates an opportunity for exposure to berylliumcontaining material or beryllium contamination must perform that work in accordance
with the KCP Chronic Beryllium Disease Prevention Program (CBDPP) that is
published in an internal procedure, Command Media Process Description 21.01.01.04.
A copy of this document as well as the DOE’s Chronic Beryllium Disease Prevention
Program published in 10CFR850 is available upon request from the KCP.
The KCP Policy regarding subcontractors as defined in the CBDPP states:
1. The KCP has established a policy to prohibit subcontractor employees from
performing beryllium work except in conditions where the expertise of the
subcontractor is needed to accomplish the work (no KCP associates possess
the expertise). In this case, the subcontractor employees must be
knowledgeable of the following:
2. The proper procedures to handle hazardous substances such as beryllium,
3. The health effects of overexposure to beryllium,
4. The beryllium medical surveillance program,
5. The proper chemical protective clothing and equipment (CPCE) needed and
the proper use of the CPCE, and
6. Specific precautions to perform the task safely, and the procedures to
perform the work.
In cases where the subcontractor employees will perform work in a manner that can
provide an opportunity for exposure, the contractor’s Site Safety Plan must address
how exposure will be controlled (minimized) for workers performing the task and
how contamination migration will be controlled. These controls must follow the
elements of the KCP CBDPP. Workers who will become beryllium workers must
also meet the following KCP Policy.
47
P. Beryllium Worker Blood Test
Any employee newly assigned to a job involving the processing of beryllium in a manner
that generates particles is required to have a blood LPT performed by Medical Care
Services. The results of this test must be normal. The test must be preformed and the
results discussed with the associate prior to beginning the beryllium processing. If the
results are found to be abnormal, the associate may not perform beryllium processing.
(Note: For subcontractors, the medical surveillance program is administered by ORISE.)
Q. Beryllium Air Monitoring
Beryllium air monitoring must be performed that is at least representative of each worker
and each task performed. Enough samples must be collected to be statistically significant.
The samples must be breathing zone samples and must be for the full-shift (or at least that
part of the shift where the beryllium exposure occurred). Documentation that no other
beryllium exposure occurred during that shift must also be submitted. The samples must
be analyzed by an AIHA certified laboratory with a minimum detection limit of 0.02
micrograms following NIOSH 7300 (current edition).
Monitoring results must be reported to Honeywell FM&T monthly during the project. The
following data must be collected and reported for each monitoring event.
Item Number
Datum Identification
Description
1
Site Code
Subcontractor does not need to provide.
2
Unique ID
Subcontractor does not need to provide.
3
Status Code
Subcontractor does not need to provide.
4
Location Identification
Location where the exposure occurred
5
Room/Area
Room/area where exposure occurred
6
Process
Free form text describing beryllium activity process
7
Operation
Free form text describing the beryllium activity operation
8
Task
Free form text describing the beryllium activity task
9
Actual Exposure
Actual exposure level or limit of quantitation during the sampling
period in μg/m3
10
Actual Exposure<LOQ
Indicate whether the actual exposure is less than the limit of
quantitation, Y/N
11
Exposure Sample Volume
The volume of air sampled in liters
12
8-hour TWA
8-hour time weighted average exposure level or limit of quantitation
in μg/m3
13
Exposure Method
Free form text describing the type of exposure method
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14
Sampling Method
Describe the sampling method used
15
Analytic Method
Describe the analytic method used
16
Exposure Sampling
Time Exposure sampling time (min.)
17
Sample Number
Sample identification number
18
Monitoring Date
Date monitoring was conducted - MM/DD/YYYY
19
Chemical
Free form text describing beryllium chemical compound
20
Engineering Controls
Free form text describing engineering controls
21
PPC&E
Personal protective clothing and equipment used? Y/N
22
Respirator Protection
Respiratory protection used? Y/N
23
Respirator APF
Respiratory protection “Assigned Protection Factor“
In summary, the contractor’s Site Safety Plan must address worker protection
(including CPCE and protections of worker’s personal clothing from beryllium
contamination), site control, contamination migration, chemical monitoring, and other
topics as appropriate for the task to be performed in concert with the DOE’s Chronic
Beryllium Disease Prevention Program (10 CFR 850) and the KCP CBDPP.
R. Moving Equipment Used to Process Beryllium
If partial disassembly must be performed in order to rig the equipment for transfer,
workers must, at a minimum, wear protective coveralls and gloves to protect skin and
personal clothing. A Beryllium Work Permit is required and a Designated Area must be
established. This work should be performed by Honeywell FM&T associates. If the size
or configuration of the equipment required expertise not available at KCP in order to
perform the rigging, provisions must be made to protect the subcontract employees.
This may be accomplished by Honeywell FM&T associates removing any panels
necessary for the rigging and decontamination of the internal surfaces of the equipment
prior to subcontractors rigging the equipment. If that is not reasonable or feasible,
subcontractors may perform the entire operation provided the subcontractor has the
ability to provide adequate protection for the workers and the work is adequately
addressed in the site safety plan.
In either case, the subcontractor employees must be made aware of the hazard by the
contractor’s safety engineer. If the second option is chosen, the names of the
employees performing the work must be given to the KCP ES&H department. Those
employees will be offered enrollment into the beryllium medical surveillance program
administered by ORISE. (Note: The KCP has a policy that prohibits subcontractors
from performing beryllium work unless the KCP does not have the expertise to perform
the intended work.)
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17. MEDICAL SURVEILLANCE PROGRAM (new)
A. Respirator Medical Monitoring Requirements
Employees required to wear respirators shall participate in a Seller coordinated medical
surveillance program that meets the requirements of 29 CFR 1910.234, Respiratory
Protection. This requires an examination prior to being issued a respirator and at least
annually thereafter.
B. Audiometric Testing
Employees who may be exposed to noise levels at or above 85 dBA 8-hour time
weighted average, without regard to hearing protection devices, are required to
participate in an audiometric testing program.
C. Additional OSHA Specific Medical Monitoring Requirements
As may be applicable to a particular job site or work activity, the Seller will adhere to
the medical monitoring requirements specified in Occupational Safety and Health
Administration (OSHA) 29 CFR 1910 Subpart Z Toxic and Hazardous Substances and
OSHA 29 CFR 1926. For example, medical monitoring programs may be required for
torch cutting activities where cadmium and/or lead exposure levels may exist. There
may be additional work practices that require implementation of the above referenced
medical monitoring requirements.
D. Hazardous Waste Operations / Clean Up
Seller personnel involved in hazardous waste operations covered under 29 CFR
1910.120, 40-hour training for hazardous waste site workers, and (HAZMAT) team
members and/or hazardous materials specialists whose job involves the use of
respiratory protection shall participate in a medical surveillance program which meets
the requirements of 29 CFR 1910.120(f).
E. Asbestos Medical Monitoring Requirements
Employees required to work in an asbestos regulated area shall participate in a medical
surveillance program that meets the requirements of 29 CFR 1926.1101, Asbestos.
This requires that a physical examination, including a pulmonary function test, be
performed prior to assignment, at least annually thereafter, and upon termination of
employment.
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18. SAFETY
A. Personal Protective Equipment Requirements
1. Protective Eyewear & Hard Hats
The Seller's personnel shall wear the appropriate personal protective equipment.
Hard hats are mandatory on all active construction sites. Safety glasses with side
shields are required in posted areas and for any work activity that could make the
eyes susceptible to injury. When drilling or chipping overhead, goggles should be
worn. Face shields shall be worn when required. If prescription glasses are worn
they must meet the ANSI Z87 requirements, or over-the-glass safety glasses should
be worn.
2. Work Clothing
Minimum clothing requirements are as follows: full-length pants, shirt and sturdy
leather work boots or shoes. Visitors to the construction site are required to
maintain the same dress code as above. For flame-resistant (FR) clothing
requirements see the electrical safety section.
3. PPE Care & Storage
All personal protective equipment used by the Seller shall be used, stored,
maintained, and replaced in accordance with applicable regulatory requirements
(i.e., respiratory equipment, fall protection, electrical personal protective equipment,
etc.).
4. Protective Footwear
Where there is the potential for hazardous conditions capable of causing foot injury,
safety toe footwear shall be worn in construction areas.
5. Fall Protection
Fall protection equipment shall be used when working six feet or more above the
floors and outside the confines of protective guardrails, or when three points of
contact on a ladder cannot be maintained. Fall protection shall be worn on projects
where such systems are required (articulated boom lifts).
Fall protection equipment shall be worn by the Seller's personnel when heights less
than six feet are particularly hazardous (i.e., when working over machinery or
objects capable of impalement).
6. PPE Identification
Contractor is responsible for identifying and requiring appropriate personal
protective equipment to be worn by their personnel beyond minimum items
described.
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B. Overhead Work Hazards (New)
The potential for overhead hazards are abundant throughout the Kansas City Plant.
These hazards include un-insulated steam lines, sprinkler heads, fiber optic cable
system, sharp objects, dust, electrical buss ducts, high voltage cable trays and
exposed electrical conductors on overhead cranes and older lighting systems. Any
project involving lifts, ladders and scaffold above 8 feet require an evaluation of the
potential hazards and the method of control used to protect the worker must be
addressed in the project AHA and the DHA.
C. Securing the Work Zone
The Seller is responsible for protecting personnel and property against potential
damage. The Seller must post the construction site with appropriate barricades and
signs. Barricades are obstructions to warn the passage of persons or vehicles into
areas where temporary hazards exist. Take into account the height of what is being
worked on. Adjust the size of the work area boundaries as necessary during the
project.
1. When working overhead, "Men Working Overhead" signs shall be prominently
displayed in all directions of travel near the work.
When the potential for falling material (bolts, hangers, nuts, pipe, insulation, etc.)
exists, barricade and protect the area and/or equipment from damage. The
Seller shall also provide an employee to be stationed below the work area to
keep unauthorized personnel out. Area shall be kept secure until all hazards are
removed from the work site.
When overhead work must be performed over false ceiling areas, additional
appropriate measures must be taken such as tethering off hand tools or laying
plywood down to protect the ceiling. Notify and coordinate with the Area Owner
so the KCP associates may be moved prior to commencement of work.
2. Acceptable barricade materials include the following:
a. High-visibility tape, yellow rope, plastic chains;
b. Rubber or plastic traffic cones;
c. Sawhorses (flasher lights for night hours);
d. Metal or wood guardrails; and
e. Portable screens.
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3. Barricades shall be used in the following instances:
a. Areas below overhead work;
b. Hazardous leaks or spills;
c. Sand or shot blasting;
d. Asbestos removal;
e. Radiography;
f. Temporary open trenches, ditches, or holes;
g. Removing machinery and equipment.
4. When circumstances dictate, the Project Engineer may approve the use of a
standby person in lieu of a barricade.
5. Always post barricades with a contact person in case of an emergency or
access is needed.
D. Safety Guardrails
Guardrails are barriers to physically prevent persons from falling through wall openings
or stepping into temporary openings. Guardrails shall be constructed of a standard top
rail, mid-rail, and toeboard and capable of withstanding 200 pounds lateral force or
provide the equivalent protective factor.
E. Moving Load Limits on Elevated Floor Slabs
Moving equipment and loads down halls within the plant may cause structural damage
to the elevated floor slab. If your project includes relocation, removal or installation of
equipment, or hauling heavy loads in the plant hallways be aware that there may be
restriction on the weight being hauled. Total weight of a moving load includes the
combined weight of the load and the weight of the fork truck, crane, wagon, dolly, etc.
Areas of concern:
•
FW29: Shoring required for all total weights exceeding 30,000 Lbs.
•
FQ29: Shoring required for all total weights exceeding 30,000 Lbs.
•
34-Aisle: FP34 Minimal shoring required for all total weights between 15,000 and
30,000 Lbs. Shoring required for all total weights exceeding 30,000 Lbs. The
beam and slab on this bay must be shored. When a special dolly is used, the
allowable load on the Q tunnel shall be increased to 20,000 lbs with no shoring.
•
FQ50-FR50: Shoring required for all total weights exceeding 12,000 Lbs.
•
FQ40: Shoring required for all total weights exceeding 12,000 Lbs.
This data is continually updated. Contact Utilities Engineering at (816) 997-5530 for
specific restrictions on the area you will be moving heavy loads across.
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F. Scaffold Tagging System
Four different tags will be used to identify various stages of scaffold erection, use and
disassembly. These tags shall be located approximately 4 feet above the floor at the
post closest to the scaffold's access ladder or point of access. KCP’s Safety
Department will provide you with the required tags.
Scaffolding tagging system:
1. CAUTION TAG -- If the scaffold cannot be built according to OSHA standards
(guard rails cannot be attached due to pipes, etc.), a yellow "CAUTION" tag shall be
completed and applied. This tag states, "This scaffold does NOT MEET
Federal/State OSHA Specifications. All employees working from this scaffold must
wear and use an approved safety harness. DO NOT ALTER.” This tag shall
remain on the scaffold as long as these conditions exist.
2. OK TAG -- If the scaffold is erected according to OSHA specifications, a green
"OK" tag shall be completed and applied. This tag states, "This scaffold has been
erected to meet Federal/State OSHA Standards and is safe for all craft work. DO
NOT ALTER. This tag shall remain on the scaffold as long as these conditions
exist.
3. INSPECTION TAG -- In addition to the "CAUTION" or the "OK" tag, a yellow
"SCAFFOLD INSPECTION" tag shall be completed and applied to the scaffold.
This inspection tag identifies, on one side, key responsibilities of the competent
person inspecting the scaffold, and on the other side, a few check off circles and
spaces for the competent person following the inspection to initial and date the tag
each day the scaffold is being used.
4. DANGER TAG-- Will be applied to the scaffold during disassembly or if scaffold
in unsafe to use.
After the scaffold is completely disassembled the tags can be discarded.
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G. Scaffolds
1. All scaffolds shall be erected and operated under supervision of a competent
person. All scaffolding over six feet in height shall have the appropriate guardrails,
mid-rails, and toe boards. If a person must pass underneath, 1/2-inch wire mesh or
equivalent shall extend along the entire opening. Unstable objects must not be
used to support scaffolds or planks. All scaffolds must be plumb, secure, and
capable of supporting, without failure, at least four times the maximum intended
load.
2. Painter or Baker scaffolds (four feet in height and less than 45 inches wide) shall
have guardrails installed on all open sides and ends of the platform. No Painters or
Bakers scaffold system extended to a walking surface height greater than four feet
will be allowed.
3. An access ladder or equivalent safe access must be provided.
4. OSHA approved scaffold planks must be overlapped a minimum of 12 inches or
secured from movement. End supports of planks must extend at least six inches
but no more than 12 inches.
5. Moveable scaffolds shall be locked in place when in use.
H. Ladders and Aerial Lifts
1. Ladders
a. No aluminum ladders are to be used or brought on site due to the
potential for contact with energized electrical systems.
b. Portable ladders in use shall be tied, blocked, or otherwise secured to
prevent displacement.
c. The top two steps of a stepladder shall not be used as a step.
d. The area around the top and bottom of ladders shall be kept clear.
e. Ladders shall not be used on slippery surfaces unless secured or
provided with slip-resistant feet to prevent displacement.
2. Aerial Lifts
a. All aerial lifts equipped with outriggers shall have the outriggers fully
extended.
b. Extendable and articulating boom lifts require that the employee be tied
off to the basket or boom when it is in use.
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I. Powder-Actuated Tools
The use of powder-actuated hand tools requires a High Hazard Construction Safety
Work Permit. The Seller shall show proof of training for those who will use
powder-actuated tools.
J. Portable Air Compressors / Pressure Vessels (new)
Any work requiring the use of portable compressed air systems must have a pressure
vessel that meets the requirements of A.S.M.E. Boiler and Pressure Vessel Code. The
system must have a pressure relief device and a pressure gauge. It is the
responsibility of the Seller to maintain the compressor system and ensure frequent
inspections and testing of all safety relief devices. Note: special care of portable air
compressors is required during freezing weather to ensure relief devices are not frozen.
K. Plant Compressed Air Systems (new)
The plant air system is capable of supplying adequate air supply for most pneumatic
tools and equipment. Connections are available throughout the plant. Contact the
project engineer for further direction. It is the Sellers responsibility to provide adequate
hose and retainer rings between hose connections and tools.
L. Helicopter Lifts
Helicopter lifts require planning between the Seller and the Project Engineer.
Appendix J, Safety Requirements for Airlifting Operations, describes minimum
requirements for a helicopter lift.
M. Cranes
If your project involves a critical or unusual type of lift, see Appendix F for additional
safety plan requirements.
Use of cranes, including in-plant overhead bridge cranes, requires a Construction
Safety Work Permit. All overhead lifts shall be coordinated through the Project
Engineer or Facilities Operations Planning Specialist. All mobile cranes must have the
most recent annual inspection form available prior to operating.
All cranes used outdoors shall remain clear of overhead power lines. Work areas must
be walked down by planners and workers to identify overhead line hazards. Should the
situation exist that the crane has the potential to contact the overhead power lines the
general contractor shall develop a two barrier control utilizing 2 of the systems
described below:
1. Trained spotters - spotters trained in the techniques of visually determining standoff
distance and in radio communication with the operator.
2. Physical boundaries - barriers that prevent the equipment from intruding within the
standoff distance.
3. Demarcation lines - stakes or painted lines that provide constant reminders to
equipment operators of the proximity.
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4. Measurement of the overhead line and equipment clearance - utilizing remote, not
direct, measurement techniques to determine the actual clearance distance.
5. Use of reflective materials - enhancing visual identification of spotters by equipment
operators.
If there are circumstances that preclude de-energizing overhead power lines, those
reasons should be documented in the work planning process and approved at the
project management level.
All hoisting and rigging equipment shall be properly maintained, inspected and marked
with WLL (working load limit) and manufacturer. Any defective rigging equipment must
be removed from the job site.
Overhead in-plant hoists and cranes are not to be used except in limited circumstances
with KCP approval. If such a circumstance arises, a letter of indemnification and hold
harmless agreement must be submitted to the project engineer. Prior to using the KCP
hoist or crane, a pre-operational inspection will be completed in the presence of a KCP
ES&H representative.
N. Excavations
Excavation - The disturbing of soil where unknown utilities may be embedded or not
visually apparent. Note that penetrations through slabs/floors/roads, etc. where the
subgrade/soil will be disturbed are also included in this definition. Utility Location &
Excavation Permits will be issued for projects that meet this definition.
The contractor on-site competent person is responsible for performing and reviewing
the activities indicated under the title on the permit. Signing of the permit indicates
confirmation that these responsibilities have been accepted and performed.
Excavations must be reviewed prior to entry and the permits reviewed weekly as a
minimum. The excavation must comply with CFR 1926.650 subpart P- Excavations.
Seller is responsible for performing work in a manner that recognizes utilities may exist
that are not identified by the Buyer’s utility locating equipment.
Underground utility drawings are provided to communicate potential known hazards;
however, there is no representation that the drawings are accurate with respect to
relational locations or the comprehensiveness of all utilities in the area.
The 30 inch rule - The 30” rule defines the exclusion zone around an underground
utility where destructive methods of excavation are prohibited. Any excavation within
30” on either side of a marked underground utility or to a depth of within 30” of an
underground utility must be performed using non-destructive excavation methods.
All soil at the Kansas City Plant should be considered class “C” for excavation and
trenching purposes. Excavation activities shall require a Utility Location & Excavation
Permit issued by Utilities Engineering Representative.
All contractors involved in trenching and excavation projects must identify and have a
competent person overseeing the activity.
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Prior to the start of the project, all potentially hazardous materials are identified and
disclosed to the Seller. However, should an excavation reveal any unsuspected soil
with unusual color, odor or appear oily stop work immediately and notify the project
engineer or project planner. Honeywell’s Waste Management Department will take soil
samples and identify the soil contaminates and proper disposal methods. Do not
dispose of any concrete or soil that appears to be contaminated without the approval of
Honeywell’s Waste Management Department.
O. Electrical Safety
1. PREMISES WIRING -- All electrical installations, modifications, and related work
shall be in accordance with the pertinent provisions of the National Electrical Code
(NEC), NFPA-70 2002 edition and the National Electrical Safety Code, ANSI C-2
2002 edition unless otherwise modified by requirements of this section. These
standards shall apply on the job site for both permanent and temporary wiring. All
electrical work shall comply with KCP construction standard specifications for
design and product specifications. All electrical work shall be subject to inspection
and shall be acceptable to the appropriate Authority Having Jurisdiction (AHJ).
2. WORK PRACTICES -- All electrical work practices shall be in accordance with
the pertinent provisions of the Standard for Electrical Safety in the Workplace,
NFPA 70-E 2004 edition and the Electrical Safety-Related Work Practices
(ESRWP) found in OSHA 1926.416 and OSHA 1910.331-.335. All required
personal protective equipment (PPE) shall be identified and supplied by the Seller
and used in the appropriate manner. All electrical work practices shall be subject to
review and shall be acceptable to the appropriate Authority Having Jurisdiction
(AHJ).
3. FLASH RESISTANT CLOTHING-- In addition to any dielectric products required
for protection from electrical shock, personnel exposed to potential electrical
hazards shall wear clothing of a type that will not contribute to an injury due to arc
flash burn or thermal burn. This clothing shall be recognized FR garments with a
minimum arc thermal performance value (APTV) of 4 for shirts, 8 for pants, or 4 for
a coverall. Clothing with a higher corresponding ATPV shall be worn if the flash
hazard is determined to exceed these values during the job hazard analysis.
4. This clothing shall be worn as a system in accordance with NFPA 70-E
“Standard for Electrical Safety In the Workplace" 2004 edition. Contractors shall
identify in their project safety plan the specific method of implementation that will be
used for determining FR clothing compliance (calculations / tables / standard
everyday work clothes).
5. HIGH VOLTAGE -- All premises wiring high voltage activities shall be conducted
in accordance with the pertinent provisions of the OSHA standards contained in
Subpart V - Power Transmission and Distribution, 29 CFR 1926.950, and Subpart R
- Power Transmission and Distribution, 29 CFR 1910.269.
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6. SHUTDOWNS -- Electrical shutdown must be coordinated and permission must
be obtained from the KCP Project Representative prior to working on any 2.4kV or
13.8kV cable or component, and on any circuit originating from or terminating in a
substation.
7. SUBSTATIONS -- All work within a Kansas City Plant substation shall be
coordinated with the KCP Project Representative, who in turn shall coordinate
access and activities with Electrical Utilities Engineering. System configuration shall
be performed by KCP Electrical Maintenance personnel following coordination with
Electrical Utilities Engineering. Verification and testing shall be conducted by the
Seller prior to initiating their work. All electrical work within substations (energized
or de-energized) shall be conducted by trained personnel using the 2-person rule.
(See Appendix H) for example of the Permit for Energized Electrical Safety
8. BUSWAYS -- Electrical shutdown must be coordinated and permission must be
obtained from the KCP Project Representative prior to working on any 480 volt
busway or bus duct, including the installation and removal of any bus plugs (tap
switches).
9. ENERGIZED WORK (updated)-- All energized work (beyond testing and
troubleshooting) must be coordinated with the Honeywell Project Representative
and a written permit obtained prior to performing electrical activities over 50 volts to
ground.
10. GFCIs -- Ground Fault Circuit Interrupter (GFCI) devices are required for
personnel protection during all construction, demolition, remodeling, maintenance,
repair, and similar activities. This protection shall be required even if using doubleinsulated tools. GFCIs shall be an integral part of the branch circuit (fixed breaker
or receptacle types) or installed directly to the premises wiring (portable plug or
portable in-line types).
In addition, GFCIs shall be used in any of the following locations:
•
Outdoors
•
On or within any wet or damp location: for example, i.e., sump pits, condensate
pits, and wet floors
•
On all building roofs
•
On conductive flooring
•
On or about grounded structures: for example, piping ducts, conduits, metal
tanks, and platforms
11. LOTO -- Lockout and Tagout of Equipment -- The Seller shall comply with the
energy control requirements of OSHA's 1926.417, 1910.147, "Control of Hazardous
Energy," and the safety requirements for both the Buyer's and Seller's
Lockout/Tagout processes (See Appendix G).
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12. FLEXIBLE CORD SETS -- Flexible cords and cables (including extension cords
and power supply cords) shall be protected from damage and abuse. Protection
shall include cable shields where exposed to pedestrian and/or vehicle traffic.
Cords shall have intact insulation, be without splice, have adequate strain relief, and
be suitable for the environment involved. All cord caps (plugs) shall be dead front,
with all blades, pins, and connector components intact. Cords shall be inspected
prior to use and shall be tagged and removed from service if any defect is identified.
13. TEMPORARY LIGHTING -- All temporary lights shall be designed or equipped
with guards to prevent accidental contact with the bulb. Temporary lighting shall not
be suspended by electrical cord unless specifically designed as the means of
suspension.
P. In-Plant Vehicles (Powered Industrial Trucks and Carts)
Each Seller vehicle, prior to use on site, shall comply with the most current In-Plant
Vehicle Safety Rules (See appendix I).
Q. Customized/Modified Heavy Equipment
When using customized/modified heavy equipment, an engineering evaluation must be
performed that defines and establishes the operational parameters (limits) of the
individual component and the equipment in its entirety. The necessary design
documents must also be independently verified to ensure that the system design
covers the particular application for which the system will be used. The operating
manual for the customized equipment should describe the boundaries of safe operation
and how to operate the system to stay within the established safe operational
boundaries as defined in the engineering evaluation document.
A training program shall be in place for operators that establish the knowledge and
skills necessary to ensure that the equipment is operated within the safe design and
operations limits defined in the engineering evaluation and the operations manual. This
training program should include a mix of academic training on the safe design and
operations envelopes and on-the-job training. On-the-job training shall address
operation within the safety limits and response to conditions outside the safety
envelopes. Training records shall be maintained on site as required in section two.
Finally, the work package/instructions shall contain controls requiring that all work be
performed in accordance with the equipment operations manual.
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R. Motor Vehicles and Mechanized Equipment
1. All construction vehicles entering the KCP shall be in proper working order. This
includes brakes, lights, alarms, etc. Posted speed limits are 8 mph inside the plant
and 15 mph outside the plant.
2. Getting on/off a construction vehicle while it is in motion is prohibited.
3. Equipment supplied with seat belts must be used during equipment operation.
4. All operators of in-plant vehicles shall attend a short ES&H training program on
vehicle requirements.
S. Steam Systems
When removing or installing insulation on steam or condensate lines contact the East
Power House at X3534. The engineer will determine if the lines can be shut down. In
most cases the steam or condensate can be shut off while the insulating activities take
place. In some cases, the lines will not be able to be shut down which will require
protective gloves and other precautions to prevent burns.
19. DRILLING INTO CONCRETE OR ASPHALT (new)
Prior to initiating a blind cut or saw cutting, drilling or jack-hammering
into a concrete/asphalt surface (examples - concrete ceilings, floors, columns, beams,
roof ribs, concrete & metal roofs, footings, foundations, exterior slab on grade (concrete
& asphalt) or suspended slabs (ramps, etc.) a penetration checklist must be completed
(See Appendix Q).
A. Penetrations Greater Than 4 Inches
Penetrations greater than 4" in depth require an electrical and non-ferrous scan
performed by a designated Honeywell FM&T Utility Locator (X2203 or X5219) prior to
drilling, saw cutting, or jack-hammering.
B. Penetrations Less Than 4 Inches
Option one: Contact FM&T Utility Locator (X2203 or X5219) to scan for buried utilities
and re-bar.
Option two: Contractor will scan for rebar and utilities in concrete/asphalt 4 inches or
less in depth. Prior to scanning for rebar and utilities the Contractor shall complete the
following actions:
•
Purchase own locating equipment (Hilti PS 20 re-bar locator or Zircon MT 6 for rebar identification or Zircon i500 for electrical and piping systems in sheet rock or
close to the surface of concrete)
•
Operators of scanning equipment must be trained by equipment representative. No
training will be provided or paid for by KCP.
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•
Trained employees shall submit scanner training documentation to Honeywell
FM&T ES&H for verification and inclusion of training on the KCP contractor training
I.D. Badge. Only trained contractor employees may scan for rebar and utilities.
No work shall be accomplished prior to the issuance of a penetration checklist. Failure
to have trained employees perform the scan will result in a citation to the general
contractor.
The penetration checklist includes a visual work site inspection, and performance of an
electrical scan on areas suspected to contain electrical utilities. Utility location cannot
assure that an energy source will not be drilled or cut into. If a reasonable level of
surety cannot be attained, all energy sources to the area should be de-energized. For
penetrations of the roof, appropriate barricading and a watch person shall be provided
under the roof where the penetration is to occur. Additionally, KCP Security must be
notified if a penetration through the roof is required.
20. ROOF WORK
A. Roof Work Notification
Prior to starting any projects on the roof, contact the maintenance roof crib (next to the roof
elevator) Notify the roof crib supervisor of your project location and the activity to be
performed. They will notify you of any concerns you may encounter while working on the
roof.
B. Temperature Drop
If the temperature is predicted to fall below 40o F for an extended time during the
shutdown period, the shutdown will be cancelled.
C. Icy Conditions
During fall and winter months the roof will become slippery with frost. We have placed ice
alert warning devices at every roof entry point. Any workers going on the roof when frost
and ice is present must take protective measures such as ice cleats or Yaktrax to prevent
slips and falls.
D. Roof Damage
Any roof work which damages roofing material (cutting, sawing, drilling, etc.) must be
repaired by the close of the business day to protect against leaks.
E. Weight Restrictions
The Project Engineer shall be consulted before any equipment or material weighing in
excess of 2,000 pounds is moved across the roof to determine the method and route to be
taken.
F. Roof Crane Use
The crane located at the north end of the main plant (bay Z-28) is rated at 2000 pounds.
Contact the roof maintenance crib for assistance. Only qualified operators shall operate
the crane. Loads in excess of its limit shall not be hoisted.
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G. Material Storage
There will be no storage of material on the roof except in specific locations constructed
expressly for the purpose of storage.
All materials that are not incorporated in the project shall be removed from the roof.
H. Roof Drains
Scrap and trash must be picked up daily to avoid blocking roof drains. Failure to do so will
result in clean-up expenses being back charged to the Seller.
I. Vehicle Standards For Use On The Roof.
•
Vehicle tires shall be pneumatic, of smooth or ribbed design, and a minimum tread
width of eight inches.
•
All vehicles must pass a roof clearance measurement and have a roof safe
inspection sticker before use on the roof.
•
All attaching devices (ball sockets) must be mounted high enough to clear roof
obstructions without catching.
•
All vehicles that will access the roof must be no longer that 9’ 4” and no loads can
extend past the 9’ 4” length to prevent elevator damage.
J. How to Proceed When KCP Floor/Roof May be Penetrated
Prior to the removal of roofing materials and/or the removal/installation of piping,
conduit, ductwork, equipment supports, anchors, pitch pans, etc. with the potential to
penetrate any KCP roof or floor that acts as a ceiling for a space below, the Seller shall:
1. Initiate and complete a visual inspection for unsecured items with Buyer
representative of the factory ceiling beneath the roof.
2. Initiate and complete a High Hazard Construction Safe Work Permit. This form
shall be signed by the Construction Manager, ES&H, and Honeywell FM&T area
owner prior to any work activities on the roof or ceiling occurring in an area.
3. Barricade with caution tape the building floor area affected by the roof work
activities and post hard hat signage around the affected area. Advise area
occupants that they may work or pass through the area but must wear hard hats.
The barricaded area shall include, at a minimum, a twenty foot buffer zone that
extends beyond expected work area above. Seller shall periodically inspect the
caution tape barricades.
4. Notify daily the Honeywell FM&T area owner and Construction Manager prior to
starting any work activities on the roof or ceiling.
If unsecured items are identified during the visual inspection the Seller shall:
1. Initiate and utilize a retrieval or catch system for unsecured items to mitigate the
potential of falling items.
63
2. Clear personnel from the barricaded area and institute measures to protect
equipment from falling objects.
3. Station a watch person inside building(s) monitoring the barricaded area using radio
communication to communicate with the Seller’s crew working above.
4. Remove and/or fasten unsecured items.
Notes:
64
•
If work activity for removal is not identified in Seller’s Safety Plan/Activity Hazard
Analysis, modify the document to include this work activity prior to performing work.
•
Installation activities that penetrate any KCP roof require the Seller to initiate and
complete a Class 2 Penetration permit.
•
This requirement also applies when installing equipment that bolts to the floor, if the
floor is also a ceiling to an area below.
21. SECURITY REQUIREMENTS
A. Security Badge Requirements (updated)
To receive a parking permit, new employees must bring vehicle license number, make and
Model the following items to the safety and security orientation:
•
A parking permit is a requirement to park in the KCP parking lots.
Employees who have been at the KCP for a period of six months or longer or performing
work on weekends may request an uncleared photo security badge. Issuance of the photo
identification badge is at the discretion of the personnel security department. Employees
must provide the following to personnel security before a badge can be issued:
•
Proof of Citizenship - a certified copy of the birth certificate. It must have the
registrar's signature and raised seal affixed. No hospital-issued birth certificates or
photo copies will be accepted.
•
Photo identification (e.g., state issued drivers license) - current or expired U.S.
passport will suffice for proof of U.S. citizenship and the photo identification.
B. Physical Security
1. All personnel must enter and exit the project site through normal or prescribed
access routes. Openings through the roof or exterior building wall shall not be used
unless authorized by the KCP Security.
2. The Seller shall notify the Project Engineer of schedules for any breaching of the
roof, the exterior wall, or the perimeter fence associated with the project. The Seller
shall give a minimum of 24 hours notice for all schedule changes. The Project
Engineer will notify Physical Security of schedule changes.
3. All roof, wall, and fence openings shall be secured to the satisfaction of the
Project Engineer and Buyer Security personnel at the end of each working day.
4. Anyone noticing suspicious activities around the facility is to contact patrol
immediately at X3600.
C. General Security Awareness
1. Overview of Safeguards and Security Program Responsibilities
The KCP security organization provides all aspects of security protection for
classified and sensitive material and information, government property, and
associates on a year-round, 24-hour, seven-days-a-week basis. Security is
provided for unclassified and classified information and material from theft and
unauthorized disclosure, destruction, and modification. Also, property and other
assets are protected against theft, sabotage, misuse, or hostile actions.
65
2. Escort Procedures
Access to secure areas at the NNSA and KCP is limited to authorized personnel
possessing access authorization and a need-to-know. Uncleared U.S. citizens, on
official business, may be granted access to the KCP office's secure areas as a
visitor. However, they must be under the control of an authorized escort with the
appropriate level of access authorization.
3. Protection of Government Property
All property purchased and used by Honeywell FM&T, as an operating contractor to
the DOE is actually the property of the United States Government.
Federal law, Honeywell FM&T's contract, and internal regulations all require that
government property be used for official government work, or as otherwise specified
by general management. Any individual accessing Honeywell FM&T facilities that
uses government property for other than specified above is subject to appropriate
disciplinary action.
D. Badge Procedures
1. The security badge you are issued must be worn at all times. Wear it so that it is
visible at all times between your shoulder and waist. Display or remove and
surrender the badge as requested at guard posts.
2. If you do not have a security clearance, you will be issued an uncleared visitor
badge. You will be assigned an authorized escort who will accompany you during
your visit. Security procedures require that you remain under the control of an
authorized escort.
E. Building Access
All construction employees with picture ID badges: (Red, L and Q) will be required
to use the turn stile for access to the facility. The main entrance will be open from
6 a.m. to 6 p.m. weekdays only. If an employee forgets his ID on off hours or
weekends, he may be denied entrance to the facility.
66
F. Identification of Controlled and Prohibited Articles
The following items are not allowed to be brought in to the Kansas City Plant unless
special provisions have been made. If you have any of the below-listed items in your
possession, you must inform the Protective Force Officer prior to accessing the facility.
•
•
•
•
•
•
•
•
•
Cellular Phones – personal, company, and government-owned
Computer equipment – including Palm Pilots, laptops, USB pen drives, and memory
sticks
Any item equipped with a data exchange port
Cameras and camera storage media– including undeveloped film and negatives
Firearms, explosives, incendiary devices
Illegal drugs, drug paraphernalia, controlled substances, alcohol
Recording and transmitting devices
o audio, video, optical, data recorders
o pagers with transmitting capabilities
o remote controlled objects
o any object with RF transmit capability
Copying devices
Binoculars and telescopes
G. Protection of Unclassified Controlled Nuclear Information
Information that is not classified is called unclassified information. Some unclassified
information may require additional protection or special handling due to its sensitivity
and the potential for adverse impact on its owners or others. Unclassified Controlled
Nuclear Information (UCNI) is one example of this type of information.
H. Procedures for Reporting Safeguards and Security Concerns
Any individual can report a Safeguards and Security Concern by contacting a security
representative or any member of KCP’s management team. You may also provide
comments or ask questions by calling the Security Hotline xSAFE (extension 7233).
I. Identification of Classification Markings
If you see a document, a part, or a container with these markings left unattended, take
into your possession and contact Patrol at x3601.
67
22. EQUIPMENT SUPPLIES AND DELIVERY
All equipment and supply deliveries are to be directed to the north side of the plant either
to the North or North East Guard houses. All delivery vehicles and their contents are
subject to search when entering or leaving the facility grounds.
Avoid deliveries to the front (south side of the facility) If deliveries come to the front (south
side) of the plant, use the Wayne and Freedom entrance and exit.
CAUTION: NO VEHICLES OVER 7’6” WILL CLEAR THE SECURITY GATES. YOUR
VEHICLE WILL SUSTAIN SERIOUS DAMMAGE! All deliveries to the front of the building
must enter and exit the facility near the railroad tracks on 95th Terrace. All delivery vehicles
will be required to pass a security inspection before being allowed to approach the
building.
No
Trucks
No
Trucks
Shipping and receiving is located adjacent to the North East Guard House. Follow the
signs and road marking across the north parking lot. Any materials shipped to KCP must
be clearly identified with the receiving company name and contact person with phone
number to expedite delivery of your package.
A.
MSB Deliveries (updated)
All deliveries to the MSB (cafeteria loading dock) will enter from the northeast gate
and pass through the cross-over to the front of the facility. Prior to entering the
crossover, honk your horn. You can expect heavy pedestrian and vehicle traffic at
any time. Pass through with extreme caution. The route is clearly marked with a
white striped driving lane.
68
23. WEATHER RESTRICTIONS
The Kansas City Plant may restrict access to the facility based on weather conditions.
Announcements will be made over the emergency notification system. There will be a
recording stating the roof is closed due to extreme conditions. The following are examples
of conditions in which we may temporarily suspend work to ensure worker safety. No
claims for compensation will be accepted by the buyer.
A. Wind conditions:
Work on the roof may be limited or stopped during high wind conditions.
B. Lightning:
If lightning is detected roof work will be suspended until conditions improve. Ground
work may also be suspended.
C. Ice/snow:
The roof becomes very slippery during ice and snow conditions. Proper ice cleats
shall be worn if winter weather conditions exist. (e.g. moisture on the roof and
temperature near freezing). If questionable, ice cleats shall be worn. Normal work
can be performed on the flat portion of the roof during winter weather conditions
with ice cleats on. Work can only be performed on the barrel portion of the roof
during winter weather conditions a potential emergency situation exists and all
employees wear ice cleats. During ice storms, all work on the roof may stop until
conditions improve.
D. Heat conditions:
During high heat and humidity conditions work schedules will be adjusted to ensure
worker safety when working outside, especially on the roof.
69
Appendix A
Construction Safety Plan Outline (updated)
The following information is provided as an outline guide for writing a site-specific construction
safety plan. Remember, your safety plan must be accepted by KCP prior to starting any
demolition and construction activities. Depending on the type of work you perform, sections that
do not apply can be omitted.
I.
Documentation Requirements
•
•
•
•
•
•
•
II.
Regulatory Guidelines
•
•
III.
OSHA requirements (29 CFR 1910/1926)
Construction Safety Handbook
General Safety and Health Provisions
•
•
•
•
•
•
•
•
•
•
•
•
70
Written safety plan
Required certified personnel
Imminent danger/stop work authority
Medical care provider
Activity Hazard Analysis
Daily Hazard Analysis
MSDS sheets
Safety and health responsibilities
Safety training and education
Recording and reporting of injuries
First aid and medical attention
Communications (tool box meetings) weekly
Fire protection and prevention
Housekeeping measures
Personal protective equipment to be provided
Acceptable certifications
Excavations and blind penetrations
Demolition plan
Lockout/Tagout
IV.
Occupational Health and Environmental Controls
•
•
•
•
•
•
•
•
•
•
V.
Personal Protective and Life Safety Equipment
•
•
•
•
•
•
VI.
First aid kits
Telephone contacts
Emergency response/evacuation and sheltering
Occupational Noise Exposure, projected levels and protective measures
Ionizing radiation, Protection Standards 10 CFR Parts 20, 34
Radiography procedures and safety measures
o Non-Ionizing radiation
o Laser safety measures
Toxic gases, mists, vapors, fumes, and dusts
Detection methods (sampling and analysis)
Ventilation
Local exhaust measures
o Duration of work in area
o Design and operation of system
o Disposal of filter media
Head protection required (Hard hats are required on all construction projects.)
Hearing protection (if sound level > 84 dBA for eight hours)
Eye and face protection (safety glasses with side shields)
Foot protection (leather shoes, no tennis shoes allowed)
Respiratory protection (selection, issuance, use and care)
Fall protection, lifelines and lanyards, required for work above six feet
Fire Protection and Prevention
•
General requirements
o Accessible fire fighting equipment
o Portable equipment
•
Fire prevention
o Identification of ignition hazards
o Indoor storage
•
Flammable and combustible liquids
o General requirements (<1 gallon)
o Indoor storage of flammable and combustible liquids
o Storage outside buildings
o Fire control for flammable or combustible liquid storage
o Temporary heating devices
71
VII.
Life Safety
•
•
•
•
VIII.
Signs, Signals, and Barricades
•
IX.
Scaffolding general requirements
Floor and Wall Openings and Stairways
•
•
72
Regulatory compliance (NEC, NFPA, ANSI)
Protection of employees
Work space around equipment
Lockout and tagging of circuits
Ground fault protection (no exceptions)
Flexible cable and cords
Ladders and Scaffolding
•
XIII.
General requirements
o Condition, maintenance
o Personal protective equipment
o Power-operated hand tools
Electrical
•
•
•
•
•
•
XII.
General housekeeping requirements
Material storage requirements
Proper disposal of waste materials
Identification of hazardous waste
Barricading requirements
Frequency of final disposal efforts
Waste isolation
Fire protection
Tools - Hand and Power
•
XI.
Accident prevention signs and tags
o Signs and symbols posting/removal responsibility
o Sign types and uses (e.g., danger, caution, exit, safety, etc.)
Materials Handling, Storage, Use, and Disposal
•
•
•
•
•
•
•
•
X.
Exit and exit signs
Emergency lighting
ENS & fire alarm
Fire protection systems
Guardrails, handrails, and covers
Guarding of open-sided floors, platforms, runways, floor and wall openings
Appendix B
Weekly Construction Safety Checklist
Project #
Location
Date
Project Title:
General Contractor:
Project Engineer:
Inspector:
This checklist covers minimum requirements. Review OSHA standards for additional inspection requirements. Turn
checklist in at the end of the month to the Safety Department.
A. General Requirements: OSHA 1926 & Construction Safety Handbook
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
Required posters and permits posted on the project board
Daily Hazard Analysis completed (DHA)
Employee and sub. safety training records reviewed, current for this project
B. Housekeeping 1926.51
Site is clean, scrap and debris removed daily or as needed
C. Sanitation 1926.50
Adequate potable water supply, sanitary conditions
Restroom available and maintained
D. Medical – First Aid 1926.50
Eyewash and showers available if required
First-aid kits available and accessible
E. Illumination 1926.52
Adequate lighting in the work area
F. Lead Program 1926.62
Compliance with lead standards for construction
Ensure painted surfaces are free of lead paint before cutting/grinding
G. Personal Protective Equipment 1926.100-107
Appropriate protection for head, eyes, feet and ears
Respiratory protection program
Fall prevention program in place for hazardous or above six feet
Appropriate protective clothing for project
Hearing protection available
H. Fire protection & prevention 1626.150-155
Fire extinguisher within 50’ of flammables
No smoking sign at flammable storage area
73
Approved storage cans in use- no plastic gas cans
I. Signs, signals, and barricades 1926.200-155
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
Adequate barricades and barriers to control the construction site
J. Cranes & Hoists 1926.550
Hand signals and load capacities posted on equipment
Annual inspection with crane
Safe distance maintained from power sources
K. Rigging 1926.251
Competent person in charge of rigging
All rigging equipment in proper condition
L. Hand & Power Tools 1926.305
Guards in place
Pneumatic lines and tools secured by whip chains or equivalent
Constant pressure switch on pipe threading machines
M. Abrasive Wheels and Tools 1926.303
Abrasive wheels properly mounted and supported
N. Welding & Cutting 1926.350-354
Acetylene cylinders stored vertically
Barriers or distance used to separate cylinders during storage
Cylinders secured in place when stored or in mobile carts
Hot work permit and water fire extinguisher in place
Appropriate holders, cables, connectors, and protective boots in use
Regulators and torch body equipped with flashback arresters
Dedicated fire watch on site during hot work
O. Electrical 1926.400-499 & NFPA 70E
Temporary wiring in compliance with NEC
LO/TO compliance, Electrical, Water, Steam
GFCI protection on hand tools
Temporary lighting per OSHA requirements
Flexible cords protected from damage (no flat cords)
Protective shirt, head gear and pants for flash protection
74
P. Scaffolding 1926.500-503
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
YES
NO
N/A
Competent person overseeing erection and inspection
Scaffold inspection tags in use
Secured to prevent swaying
Sill plates in place
Q. Fall protection 1926.500-503
Fall protection in use over six feet
Guardrail systems in place
Areas around dangerous equipment properly guarded
Fall protection systems developed for elevated work
R. Excavations & Shoring 1926.650-653
Spoils 2’ or more from edge of excavation
Roads supported and protected
Access ladder installed and used
Atmospheres tested as needed
Fencing in place to protect hole
S. Concrete forms & shoring 1926.700-702
Limited access zone
Impalement and abrasion hazard protected
T. Environmental protection
Compliance with waste management plan with project
Control of hazardous wastes, spills and dust generation
All powered industrial equipment free of leakage
U. Means of Egress, OSHA 1926.34
Exits marked
Exits not blocked
V. Hazard Communications 1910.1200 & 49 CFR 172
All containers properly labeled. The outside says what’s on the inside?
There is an established HAZCOM program?
MSDS’s are available to employees onsite?
SH1 Rev. 4 10/05 J. Nelson
75
Appendix C
76
Appendix D
Citation Example
OCCUPATIONAL SAFETY AND HEALTH CITATION
SELLER:
An inspection of your workplace was performed on_____. On the basis of this inspection,
you were found to have violated Occupational Safety Health Standards in the following
respects.
Citation # Plant Location
Standard Being Violated
Days to correct
Honeywell Inspector
NNSA Inspector (If Required)
Any employee or representative of employees who believes that any period of time fixed
in these Citations for the correction of a violation is unreasonable has the right to
contest such time for correction by filing a notice with the Honeywell Purchasing Agent
within 15 working days of the date this citations was posted.
Date Posted at Location:
77
CITATION RESPONSE REQUIREMENTS
Responses to Citations must be answered with formal documentation. The following
areas should be included in the response:
•
Root Cause (most basic reason which, if corrected, will prevent recurrence of the
incident) that resulted in the citation. Additional causal factors which affected the
incident may be listed.
•
What activities or programs were affected immediately to resolve the situation.
•
What activities or actions shall be initiated to prevent recurrence of the situation in
the future.
•
A time schedule of when the activities or actions were/will be accomplished.
•
Copies of all documentation generated by Seller in resolution to the incident.
WARNING/CITATION PROCESS
78
1.
Three warnings in a thirty-day time period for a similar concern will result in
the issuance of a citation.
2.
Conditions for removal from the bidders list:
•
Two citations in thirty days results in a thirty-day removal from bidders list.
•
Any additional citations in the same thirty-day timeframe results in an
additional thirty days removal from the bidders list for each citation.
•
Six citations in twelve months result in a twelve-month removal from the
bidders list.
•
Ten citations in twelve months result in an indefinite removal from the
bidders list.
Appendix E
DOE F 5484.3
U.S. Department of Energy
DOE F 5484.3
OMB Control No.
(xx-xx)
1910-0300
INDIVIDUAL ACCIDENT/INCIDENT REPORT
All Other Editions
Are Obsolete
Information about the Organization
Organization Name:
Department/Division/ID Code:
Organization Code:
Program Office Symbol:
NAICS Code:
Information about the Employee
1) Full Name:
2) S.S/ID Number:
3) Home Address(Street/City/State/Zip):
4) Date of Birth (YYYYMMDD):
5) Date of Hire (YYYYMMDD):
6) Gender:
8) Occupation Code:
7) Job Title:
9) Experience on this job/equipment:
10) Length of employment:
79
Information about the Physician or Other Health Care Professional
11) Name of physician or other health care professional:
12) If treatment was given away from worksite, where was it given? (Provide Name of facility and full address)
13) Was employee treated in an emergency room?
14) Was employee hospitalized overnight as an in-patient?
Information about the Case
15) Case number:
Multi-Org Case?:
Multi-Case Number:
16) Accident Type:
17) Investigation Type:
18) Accident Place:
19) On Employer's Premises:
20) Specific Location:
21) Date of Injury or Illness (YYYYMMDD):
22) Time employee began work (military):
23) Is time of event known:
24) Time of event (military):
25) OSHA Injury/Illness Classification:
Injury
26) Number of days away from work:
27) Number of days of restricted work activity or job
transfer:
28) Permanent transfer to a different job because of disability due to accident:
29) Terminated because of disability due to accident:
80
30) Is the case closed:
Information about the Case --- Continued
31) ACTIVITY: What was the employee doing just before the incident occurred? Describe the activity as well as the tools,
equipment, or material the employee was using. Be specific. Examples: 'climbing a ladder while carrying roofing
materials'; 'spraying chlorine from hand sprayer'; 'daily computer key-entry.'
31-a) Activity code:
32) EVENT: What happened? Tell us how the injury occurred. Examples: 'When ladder slipped on wet floor, worker fell
20 feet'; 'Worker was sprayed with chlorine when gasket broke during replacement'; 'Worker developed soreness in wrist
over time.'
32-a) Event code:
33) NATURE of Injury/Illness: What was the injury or illness? Tell us the part of body that was affected and how it was
affected; be more specific than 'hurt','pain', or 'sore.' Examples: 'strained back'; 'chemical burn, hand'; 'carpal tunnel
syndrome.'
33-a) Nature code:
33-b) Part of body affected code:
34) OBJECT: What object or substance directly harmed the employee? Examples: 'concrete floor';'chlorine';'radial arm
saw.' If this question does not apply to the incident leave it blank.
81
34-a) Primary object or substance (Source) code:
34-b) Other objects or substances: -
34-c) Did equipment design or defect contribute to accident cause or severity?
34-d) Personal protective equipment code (PPE being used by employee at the time of event):
35) Did the employee die? [ ] Yes [ ] No
If 'Yes', enter date of death (YYYYMMDD)
36) CAUSES: State the conditions that existed at the time of the event, the actions on the part of the employee that
contributed to the incident, and the factors or underlying causes that contributed to the incident.
Conditions:
Actions:
Factors:
36-a) Direct cause: -
Contributing causes:
Root cause:
37) CORRECTIVE ACTIONS: Describe actions taken or recommended to prevent recurrence of the incident
Actions Taken:
Actions Recommended:
82
Implementation date for recommended corrective actions (YYYYMMDD):
Name of Person Who Completed Form:
Phone:
Title:
Date:(YYYYMMDD)
Supervisor responsible for corrective actions:
Phone:
Signature Date:
Accident investigation contact (if different from person who
completed the form):
Phone:
83
Appendix F
Critical/Unusual Lift Plan
“Critical Lift” – The lift of any item when any of the following conditions exist:
•
Load is over 90% of cranes’ rated capacity.
•
Two or more cranes/booms are required or load will be rotated from vertical to
horizontal or vica/versa.
•
Potential exists for release of radioactive/hazardous material due to collision or
upset of load.
•
Potential to cause a significant work delay, or inflict monetary value damage of
$250,000 or greater.
“Unusual Lift” – The lift of any item when any of the following conditions exist:
•
Approximate weight is unknown.
•
Approximate center of gravity is unknown.
•
Manufacturer/Vendor recommended pick points are unknown.
•
Load is rotated from the vertical to horizontal or horizontal to vertical planes.
Critical / Unusual Lift Plan
The following criteria shall be included in your safety plan or added as an addendum to your
site-specific safety plan.
For all critical/unusual lifts, as defined in the definition section above, the following shall be
completed:
Appoint a person-in-charge (PIC) of the lifting operation.
Ensure all operators are knowledgeable and experienced with lifting equipment.
Review and define barricade area to include potential fall radius of hoisting equipment and
the load.
Submit the plan for comment by FES Project Engineer and Honeywell Safety & Health
Department. A Construction Safe Work Permit will be issued with notice to proceed for
commencing the operation.
Conduct a pre-lift meeting with participants (including area owner) which involves reviewing
the critical lift plan and procedures, and resolving all questions and safety issues.
84
The following items shall be taken into consideration and addressed when preparing your lift plan
for equipment to be moved:
•
Weight
•
Dimensions
•
Center of gravity
•
Manufacturers installation/lifting instructions
•
Presence of hazardous or toxic chemicals
•
Identification of operating equipment (cranes, fork trucks, and/or hoists to be used by type
and rated capacity)
Rigging sketches shall include, as applicable:
•
Identification and rated capacity of slings, lifting devices and rigging accessories
•
Load-indicating devices
•
Load vectors
•
Lifting points
•
Sling angles
•
Boom and swing angles
•
Method of attachment
•
Crane orientations, and
•
Other factors affecting equipment capacity
85
Appendix G
Safety Requirements for Contractor Lockout/Tagout
GENERAL
This procedure outlines the Kansas City Plant (KCP) minimum requirements for the
control of hazardous energy by lockout and tagout of energy-isolating devices for
contractors. It shall be implemented prior to any servicing or maintenance of a machine,
system or piece of equipment. The purpose of this procedure is to ensure effective
isolation of all potentially hazardous energy prior to personnel working on the machine,
equipment, or system, and to ensure safe re-energization. This procedure applies to
construction and construction-related service contractors. Contractor locks will be gold
in color.
TRAINING
Any seller employee whose work requires lockout tagout must attend KCP’s lockout
tagout training program. All employees approved to perform lockout/tagout are
identified on their training badges.
REGULATIONS
29 CFR 1910.147 Control of Hazardous Energy
29 CFR 1926.416 General Requirements
29 CFR 1926.417 Lockout and Tagging of Circuits
29 CFR 1926.449 Definitions Applicable to this Subpart
FORMS USED
86
•
Pre-Removal of Lockout Tagout Device (E-1484A)
•
Post-Removal of Lockout Tagout Device (E-1484B)
•
"DANGER Do Not Operate" Tag (Standardized)
Authorized - Employee who locks out or tags out equipment in order to perform service
on that equipment.
Contractor or Seller - Party or parties who are under contract with Buyer to perform
construction activities and are referred to as Seller.
De-energized - A machine, equipment, or system which is isolated from all energy
sources and is free from all residual and stored energy. A machine, equipment, or
system that is in the "Zero-energy, Energy-free or Neutral" state.
Designated Authorized Person - Individual designated as responsible for group LOTO.
Energized - A machine, system or piece of equipment connected to an energy source or
containing residual or stored energy.
Energy-Isolating Device - Equipment components that are used to physically isolate
energy. These include valves, breakers, disconnect switches, etc.
Energy Types - Any form of electrical, mechanical, hydraulic, pneumatic, thermal,
chemical, or other energy which may be supplied directly or contained in some stored
capacity.
KCP - Kansas City Plant
Lockout - The process of placing a positive locking device on an energy-isolating device
in accordance with established procedures. Used to ensure equipment is controlled and
cannot be operated until this positive restraint is removed.
LOTO - Acronym for Lockout-Tagout
Qualified Person - A person familiar with the construction and operation of the affected
equipment and knowledgeable of hazards presented by equipment and needing LOTO.
Standardized DANGER Tag (Red-tag) - A laminated, serialized, reusable "DANGER"
tag which indicates in writing the hazard that is present, the responsible employee, and
the date. Used when activation of a device could cause death or serious injury to
personnel. Only danger tags can be used in LOTO situations.
Tagout - The process of placing a warning device and positive attachment device on an
energy-isolating device in accordance with established procedures. Used to indicate
that equipment must not be operated until this warning device is removed.
87
I.
OVERVIEW
A.
Scope
Lockout and tagout are required for all servicing and maintenance of machines,
equipment, and systems in which the unexpected energization or startup of the
machine, equipment, or system, or the release of stored energy could cause
injury to personnel. LOTO may only be applied by authorized personnel.
Activities which occur during normal production operations do not require
lockout/tagout. These activities include minor tool changes and adjustments and
other minor servicing which is routine, repetitive and integral to the use of the
equipment and does not expose the employee to additional hazards.
LOTO does not apply when working on equipment with a cord and plug
connection if exposure to unexpected start-up is controlled by unplugging the unit
from its energy source. The authorized person must have exclusive control of the
plug. LOTO does not apply to hot tap operations on pressurized pipe involving
transmission and distribution systems for utilities provided when any of the
following occurs.
1. Continuity of service is essential.
2. Shutdown is not authorized,.
3. Documented procedures are followed.
4. Special equipment is used which provides proven effective protection to the
employees.
LOTO applies to equipment service when any of the following occurs.
1. A guard, interlock or other safety device is removed or bypassed.
2. An employee places part of the body into an area on a machine,
equipment, or system or into an associated danger zone where work is being
performed upon the material being processed (point of operation) or where an
associated danger exists during equipment operating cycle.
3. Employee(s) are exposed to hazardous energy sources with:
88
•
voltage greater than 50 volts,
•
water pressure greater than 100 psi, and
•
temperature extremes less than 35F or higher than 100F.
II.
PROGRAM IMPLEMENTATION
A.
Construction Contractor Responsibilities
1. Contractor Supervisors or Safety Engineer shall:
a. Ensure new or transferred employees to their company have completed
the KCP LOTO training and quiz prior to attending the site orientation. The
training will be given by the general contractor’s safety engineer.
b. Ensure all employees in their company receive the required equipment for
lockout and tagout while employed at the KCP.
c.
Monitor their responsible work operations for compliance with LOTO
requirements.
d. Complete a Pre-Removal of Lockout Tagout Device and Post-Removal of
Lockout Tagout Device if activities necessitate the removal of any other
employee's LOTO device.
e. Ensure locks, keys, and tags are returned to ES&H upon employee's
transfer or termination from the Kansas City Plant.
g. Return missing or damaged equipment to KCP’s Safety Department.
B.
Equipment Storage
1. Personnel must store all LOTO equipment in a manner which will protect it
from loss, damage, and abuse.
2. Lockout locks are considered "exclusive use" devices and must be stored
inside desks, lockers, tool carts, tool boxes, or similar locations. Lockout locks
are expressly prohibited from being used as general duty locks to lock lockers,
tool carts, etc.
3. Each employee shall be able to account for his or her personal LOTO devices
at all times.
C.
Equipment Return
When you are finished working at the Kansas City Plant, be sure to return all
lockout equipment. Any missing equipment will be back charged to the
contractor.
89
III.
PROCEDURE
Electrical, Pneumatic, Hydraulic, Mechanical, Stored, Chemical and Stored Energy
A.
LOTO Sequence
1. Survey the work operations and physically identify all isolating devices to be
certain which switch(s), valve(s), or other energy-isolating devices apply to the
equipment to be locked and tagged out. More than one type of energy
(electrical, mechanical, etc.) and/or energy source (dual-fed equipment) may
be involved.
2. Notify affected employees that lockout and tagout will occur.
3. If the machine, equipment, or system is operating, it should be shut down
using the normal shutdown procedure (depress "stop" button, turn switch to
"off" position, open toggle switch, etc.). This should be a normal, routine,
orderly shutdown.
4. Operate the previously identified switch, disconnect, valve, or other
energy-isolating device(s) so that the machine, equipment, or system is
isolated from its energy source(s). Apply LOTO and test system.
5. Ensure that any stored energy (springs, tension, elevated machine members,
rotating flywheels, hydraulic systems, electrical energy, counterweights,
air/gas/steam/water pressure, etc.) is
a. Dissipated--by bleeding;
b. Restrained--by repositioning, blocking, wedging, chaining; and
c. Disconnected.
If the possibility exists for energy to re-accumulate through capacitance,
inductance (electrical), or some other means, a system to continually dissipate
this energy (such as shorts and grounds-electrical) must be applied and
continued until the servicing or maintenance is complete or until the possibility
of such accumulation no longer exists. Zero energy must be verified.
Verify that energy has been isolated by attempting to operate the equipment. When
assured the equipment is isolated, position all controls to off or neutral position.
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6. For chemical or thermal energy types:
a. Shut off the equipment.
b. Attach LOTO devices.
c. Dissipate excess stored chemical or thermal energy.
d. Contact the Project Engineer if there are any questions that arise
concerning the hazards of the chemicals.
e. Verify energy is isolated by attempting to operate the equipment.
f. When assured the equipment is isolated, position all controls to off
or neutral position.
7. Install the lockout device and affix tagout device to each of the previously
identified and activated energy-isolating devices in the following prescribed
manner.
a. The lock shall be applied to prevent activation of the isolating device.
b. The standardized danger tag shall be legibly completed in lead or grease
pencil to identify the date, reason for lockout, company name and identity
of the authorized employee performing the lockout and tagout. Also
include a contact telephone number.
c. When the installation of the lockout/tagout device(s) is performed by a
single employee, apply the assigned individual lock(s) and standardized
danger tag(s).
d. If more than one individual will be working on the machine, equipment, or
system, each must place his/her own personal LOTO device(s) on the
energy-isolating device(s).
•
For cut-out switches and valves which do not accept multiple locks or
tags, a multiple lock hasp is available. Each employee will apply their
own personal lock and tag. As each person completes their duties and
no longer needs to maintain the lockout protection, that person will
remove their own lock and tag from the hasp.
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e. Group Lockout and Tagout
When servicing and/or maintenance is performed by group, they shall
utilize a procedure that affords the employees a level of protection
equivalent to that provided by the implementation of a personal
lockout-tagout.
Group lockout and tagout devices shall be used according to LOTO and/or
a specifically defined energy control procedure that may be required to
perform the work in a safe manner. The following specific requirements
shall be included as a minimum.
•
Primary responsibility is vested in a designated authorized employee for
a set number of employees working under the protection of a group
LOTO.
•
All employees must be knowledgeable of their responsibilities for the
group lockout. The designated authorized employee shall brief all
employees and ensure they understand their duties.
•
When more than one crew, craft, etc. is involved, LOTO responsibility is
designated to one authorized employee. This person shall be
designated to coordinate affected work forces and ensure continuity of
protection.
•
Each authorized employee shall affix a personal LOTO device to the
group lockout device or group lockbox or comparable mechanism as
each individual begins work. They shall remove the device as they
complete their portion of the work. When the group has completed
work on the machine or equipment being serviced or maintained, each
personal LOTO device must have been removed. Group lockout boxes
are available through the KCP Safety Department.
8. Ensure that no personnel are exposed to operational hazards of the machine,
equipment, or system and operate the normal operating controls in an attempt
to activate the device or system. This is to verify that the equipment has been
effectively disconnected and cannot operate.
CAUTION: RETURN OPERATING CONTROL(S) TO THE "NEUTRAL" OR
"OFF" POSITION AFTER THIS TEST. THIS WILL MINIMIZE THE POTENTIAL
OF AUTOMATIC MACHINE CYCLE UPON RE-ENERGIZATION.
92
If working on a machine, equipment, or system in which an employee may be
exposed to electrical energy, a qualified electrician must participate in the
lockout procedure to verify proper isolation and de-energization. Electricians
shall follow the live-dead-live rule outlined in this handbook.
B.
Restoration Sequence
If a single employee has locked and tagged a machine, equipment, or system,
he or she shall be responsible to ensure proper restoration of energy. If more
than one employee has applied their lock(s) and tag(s), the last person
removing his/her LOTO devices shall be responsible for ensuring proper
restoration of energy.
When service and maintenance on the equipment is complete, it may be restored
to operating condition in the following manner:
1. Inspect the area around the machine, equipment or system.
2. Ensure that tools have been removed, guards are reinstalled, interlocks
are reactivated, the equipment components are operationally intact, and
that other employees working on the machine, equipment, or system are
aware that re-energization will occur immediately.
3. Notify personnel in the area that controls are being removed from the
isolating device and that re-energization will occur immediately. Ensure
affected contractor and KCP associate have been safely positioned or
removed from the area.
4. Remove personal LOTO devices and restore energy.
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IV.
UNUSUAL SITUATIONS
A. Removal of Lockout-Tagout Devices by Supervision
It is the Kansas City Plant policy that the person who applies a LOTO device shall
be the person to remove it. Exceptions to this policy shall require the completion
of a Pre- and Post-Removal Form by the immediate Supervisor of the employee
who attached the device(s), if available, or the Project Engineer.
1. The Supervisor must document the need to remove the LOTO device(s).
2. Verify that the employee who applied the device(s) is not at the facility.
3. Make all reasonable efforts to contact the employee or to inform him/her that
the LOTO device(s) has been removed.
4. Contact the Project Engineer, complete the pre-removal form and forward
completed form to the KCP Safety Department. The lock or multi-lock hasp
should then be removed.
5. Ensure that the original employee whose LOTO equipment was removed has
knowledge that his/her LOTO device(s) was removed prior to resuming work
at the facility.
6. Return all removed locks and post removal form to the Kansas City Plant.
NOTE: Shift or personnel changes must maintain effective lockout-tagout
protection. Employees shall not remove personal LOTO devices in
anticipation of attachment of another employee's LOTO devices.
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B.
Tagout Exception When Lockout Not Required/Not Possible
1. Standardized danger tags
Tagout alone, without physical lockout, is permitted when standardized danger
tags are used to identify equipment status. No personnel hazard(s) may be
present.
If complete lockout and tagout is not reasonably possible (energy-isolating
device is not capable of being locked out without dismantling, rebuilding, or
replacing the device), tagout may be used as the means of identifying that an
energy-isolating device must not be activated. The following steps must be
taken to implement this tagout exception (1926.417(3)(i-7)).
a. Supervision must be notified that complete lockout and tagout is not
reasonably possible.
b. A Supervisor must review the machine, equipment, or system to verify
positive lockout is not reasonably possible.
c. A Supervisor must observe employee performing proper tagout and, where
possible, assign an additional employee to remain at energy-isolating
device until completion of the work.
The tagout procedure should follow the Lockout Sequence previously
identified in Section III.A.
Tagout requires that standardized danger tags be securely attached to the
energy-isolating device so they cannot be inadvertently or accidentally
detached. The Kansas City Plant requires the use of cable tie devices to
secure standardized tags to energy-isolating devices. If tags cannot be affixed
directly to the energy-isolating device, they shall be located as close as safely
possible, in a position immediately obvious to anyone attempting to operate
the energy-isolating device.
Tags or locks are not to be removed, bypassed, ignored, tampered with, or in
any way defeated without specific authorization.
95
C.
Testing/Repositioning Exceptions to Lockout-Tagout
For testing and repositioning purposes ONLY, lockout devices may be temporarily
removed by the employee and the machine, equipment, or system energized.
The previously identified procedure for removal of these devices and application
(reapplication) of these devices (Section III.B) shall be followed. Locks shall be
removed only for the period of testing and realignment and shall be immediately
reapplied.
Where testing or repositioning involves hazards such as energized circuits, etc.,
appropriate personal protective equipment shall be utilized. Other personnel in
the area shall be notified that energized/hazardous work is being conducted.
D.
Unauthorized Tampering With Lockout
Any employee who has performed a lockout and leaves it unattended should
inspect the lockout upon return to verify it has not been defeated. Any indication
of tampering or damage should be promptly reported to the employee's
supervision and the Project Engineer for investigation.
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97
Appendix H
Permit for Energized Electrical Task (PEET)
Permit for Energized Electrical Task example (new)
98
99
100
101
Appendix I
In-Plant Vehicle Operations Standards
1. The Kansas City Plant will provide two registration plates for each vehicle that will
remain on site. They are to be attached to both sides of the vehicle.
2. If the vehicle or equipment will be on site for a short time, 60 days or less, a rental
equipment identification sticker will take the place of the registration plates.
3. The Honeywell Contractor Vehicle safety inspection form (3018) shall be filled out
by the vehicle operator daily. Return the form to KCP Safety Department at the
end of the month.
4. Attachments must be a positive coupling hitch to prevent runaway carts.
5. Each contractor must maintain all vehicles in a safe and operable condition at all
times. Vehicles which need repairs shall not be used until properly repaired.
6. All in-plant vehicles must be equipped with a flashing yellow xenon strobe and on/off
switch.
7. The MSB cross-over will be closed to vehicle traffic during lunch period (11:00 am to
12:00 pm) and inclement weather to prevent tracking water into the plant.
8. Upon the completion of the contracts, vehicle plates shall be returned.
9. Vehicle activity within the plant shall be kept to a minimum.
10. All vehicular accidents and close calls shall be reported immediately to ES&H at
extension 3181.
11. All designated drivers shall attend a site safety driver orientation.
12. Failure to operate the vehicle in a safe and courteous manner will result in suspension
of the operators driving privileges from three months to complete loss of privileges.
Remember: The use of vehicles for personnel transportation is a privilege and
NOT A RIGHT!
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General Vehicle Rules
The definition of in-plant vehicle shall include tricycles, fork trucks, tractors, platform lift
trucks, motorized hand trucks, and other specialized industrial trucks powered by electric
motors or internal combustion engines. All operators of in-plant vehicles shall abide by
the following standards of operation at KCP. Failure to comply with these standards could
result in the revocation of their KCP driving privileges.
1.
In-plant vehicles shall not be driven up to anyone standing in front of a
bench or other fixed object.
2.
No person shall be allowed to stand or pass under the elevated portion of
any vehicle, whether loaded or empty.
3.
Personnel shall not be permitted to ride on in-plant vehicles not designed
for passengers. A safe place shall be provided when riding is authorized.
4.
Operators and passengers shall keep their arms and legs within the
running lines of the vehicle. Arms and legs shall not be placed between
the uprights of the masts on vehicles with lifts.
5.
When unattended, vehicles will be turned off, brakes set, load-engaging
means will be fully lowered, and controls neutralized. If parked on an
incline, the vehicle must be chocked. (Note: A vehicle is unattended if the
operator is 25 feet or more away from the vehicle or any time the operator
is not within view of the vehicle.)
6.
Prior to dismounting to perform ancillary tasks within 25 feet of the vehicle,
the operator must set brakes, lower load-engaging means, and neutralize
the controls.
7.
A safe distance shall be maintained from the edges of ramps and platforms
while on any elevated surface. Vehicles shall not be used to open or close
freight doors.
8.
While loading or unloading trucks or trailers, their wheels will be chocked
or they will be dock-locked to prevent them from moving. Prior to entering,
the flooring of the truck or trailer shall be checked for soundness.
9.
The driver shall ensure there is sufficient headroom under overhead
installations (lights, piping, sprinklers, etc.).
10.
High-lift fork trucks shall be equipped with an overhead guard.
11.
A load backrest extension shall be used to minimize the possibility of the
load or any part of it from falling rearward.
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104
12.
Vehicles shall not be parked where they could hinder or block access to
stairways or fire aisles, fire equipment, electrical equipment controls, or
emergency equipment.
13.
Vehicles shall not exceed 8 mph while in the plant nor 15 mph while
outside on plant properties. Under all conditions the vehicle must not be
allowed to exceed that speed which allows a smooth safe stop.
14.
The proper following distance is at least three vehicle lengths from the
vehicle ahead.
15.
The operator shall keep the vehicle under control at all times.
16.
The right-of-way shall be yielded to emergency vehicles.
17.
Pedestrians have the right-of-way during normal operation. Pedestrians
are required to give the right-of-way to properly identified emergency
vehicles.
18.
Other in-plant vehicles traveling in the same direction shall not be passed
at intersections, blind spots, or other dangerous locations.
19.
The driver shall stop and sound the vehicle horn at cross aisles or other
locations where vision is obstructed.
20.
If the load being carried obstructs forward view, the driver shall travel with
the load trailing.
21.
The driver shall look in the direction of and keep a clear view of the path of
travel.
22.
All grades shall be ascended or descended slowly.
23.
When ascending or descending grades of more than 10%, loaded fork
trucks will be driven with the load upgrade.
24.
On all grades the load-engaging means shall be tilted back, if applicable,
and raised only as far as necessary to clear the road surface (no more
than 3 inches from floor).
25.
Stunt driving or horseplay shall not be permitted.
26.
Drivers shall slow down while driving on wet or slippery surfaces.
27.
Drivers shall utilize seatbelts on those vehicles equipped with seatbelts.
28.
Dock boards or bridgeplates shall be properly secured before they are
driven over. They shall be driven over carefully and their rated capacity
never exceeded.
29.
Elevators shall be approached slowly and entered squarely after the
elevator car is properly leveled. Once in the elevator, the vehicle controls
shall be neutralized, power turned off, and the brakes set.
30.
Motorized hand trucks must enter the elevator or other confined areas with
load end forward.
31.
Operators shall avoid running over loose objects on the roadway surface.
32.
Operators shall slow to a safe turning speed prior to negotiating turns.
Turns shall be accomplished rotating the hand steering wheel in a smooth,
sweeping motion. Except when operating at a very low speed, the hand
steering wheel shall be turned at a moderate, even rate.
33.
Only stable and safely arranged loads shall be handled. Caution shall be
exercised when handling off-center loads which cannot be balanced.
34.
Only loads within the rated capacity of the in-plant vehicle shall be
handled.
35.
Long or high (including multiple-tiered) loads which may affect vehicle
capacity shall be adjusted.
36.
Fork trucks equipped with attachments shall be operated as partially
loaded when not handling a load.
37.
A load-engaging means shall be placed under the load as far as possible;
the mast shall be carefully tilted backward to stabilize the load.
38.
Extreme care shall be used when tilting the load forward or backward,
particularly with tall loads. Tilting forward with the load-engaging means
elevated shall be prohibited except to pick up the load. An elevated load
shall not be tilted forward except when the load is in the deposit position
over a rack or stack. When stacking, only enough backward tilt to stabilize
the load shall be used.
39.
If at any time an in-plant vehicle is found to be in any need of repair, defective,
or in any way unsafe, the vehicle shall be taken out of service until it has been
restored to safe operating condition.
40.
Fuel tanks shall not be filled with the engine running.
41.
In the event of spillage of oil or fuel, Waste Management shall be
contracted at extension 7745. All spillage must be properly contained and
removed prior to replacing the fuel cap and restarting the engine.
42.
No vehicle shall be operated with a leak in the fuel system.
43.
Open flames shall not be used for checking electrolyte level on storage
batteries or gasoline level in fuel tanks.
44.
Any in-plant vehicle that is not in safe operating condition shall be removed
from service until properly repaired by authorized personnel.
45.
Only parts meeting original specifications shall be used when repairing
in-plant vehicles.
105
46.
Additional counter-weighting of fork trucks shall not be done unless
approved by the truck manufacturer in writing.
47.
In-plant vehicles shall be inspected daily. These inspections will be
recorded on Honeywell Contractor Vehicle Inspection (Form 3018). If the
vehicle is used on a round-the-clock basis, they shall be examined prior to
each shift. Defects, when found, shall be immediately reported and
corrected. At the end of the month, turn the completed form into ES&H for
record keeping.
48.
In-plant vehicles shall be kept in a clean condition, free of dirt, excess oil,
and grease. Several times a year we hold a car wash for contractor
vehicles used on-site.
49.
Vehicles shall not pass through the MSB cross over during lunch period.
•
106
11:00 a.m. to 12:00 p.m.
50.
Vehicles shall not be used for personal convenience.
51.
A pennant of reasonable size and of a highly visible color shall be attached
to any item extending beyond the confines of the vehicle. Any item
extending more than three feet beyond the front or rear of the vehicle shall
require a pedestrian escort to warn other pedestrians of its existence.
52.
No one shall be permitted to be lifted or transported on the truck forks.
53.
Towed equipment must be secured to the towing vehicle with a positive
coupling hitch. Seller shall not use chains, straps, ropes, cables, or wire to
secure the towed vehicle to the towing vehicle.
54.
All fork truck operators must have proof of successfully completing a
vehicle operators training course prior to operating a fork truck at the
KCP.
54.
Operators shall bring the vehicle to a complete stop at all yellow stop lines and
other designated locations prior to proceeding.
Appendix J
Safety Requirements for Airlifting Operations
SAFETY REQUIREMENTS FOR AIRLIFTING OPERATIONS
The following safety requirements shall apply to all airlifting operations.
A.
The most recent versions of applicable safety regulations including OSHA
Safety and Health Regulation, 29 CFR 1926.551, Helicopters and
Aeronautics and Space, 14 CFR 133, Rotorcraft External Load Operations.
B.
In addition to any other insurance requirements to this project, Seller shall
provide proof of insurance of any subcontractor involved in airlifting
operations adequate to meet the minimum requirements of 14 CFR 205.
Copies of the certification shall be submitted with the lift plan documents.
C.
Operations involving the airlifting and placement of equipment and material
on building roofs shall be coordinated among all parties involved. The plan
of the lift, a safety plan and critical /unusual lift plan shall be generated and
submitted to the Buyer's Project Engineer through Purchasing at least
thirty (30) days prior to commencement of helicopter lift activity.
D.
No landings are allowed on the roof.
E.
Staging and landing area will be coordinated through the Project Engineer.
F.
Helicopter operations shall be performed during daylight and in weather
consistent with safe operations.
G.
Copies of certification required by 14 CFR 133 regarding the pilot and
aircraft to be used must be submitted with the lift plan.
H.
The Seller is responsible for obtaining certified proofs of the weights of all
new equipment that will be placed on the roof. These certificates shall be
forwarded to the Buyer prior to delivery of the materials. Existing materials
removed from the roof will not be of a size or weight that exceeds the
rotorcraft's capability.
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I.
Seller shall not commence operations until the Project Engineer verifies that the
following safety measures:
1. No person other than those directly involved or supervising in the operation
shall be allowed on the roof closer than 150 feet from either side of the
helicopter's planned flight path.
2. Areas within the building over which the airlift operations are in progress shall
be vacated of occupants to a minimum distance of 150 feet either side of the
helicopter's planned flight path. Patrol Headquarters (Building 75) is
exempted from this requirement; however, there shall be no flights over Patrol
Headquarters.
3. The Kansas City Plant shall provide a diked fuel storage area at the
landing/fueling area prior to the arrival of the helicopter. Buyer will provide
material required for construction of the dike.
4. The Kansas City Plant shall dike and seal all storm sewer inlets within 100 feet
of the landing/fueling area prior to arrival of the helicopter. Buyer will provide
material required for diking of the storm sewer inlets.
5. Seller shall ensure that all loose materials in the flight path are removed or
secured prior to the arrival of the helicopter.
6. Seller shall verify that the helicopter is not loaded beyond its rated lift capacity
or its safe lift capacity considering actual lift conditions.
J.
The Lift Safety Plan will address all areas identified in 29 CFR 1926.551 as a
minimum.
K.
Seller shall comply with applicable regulations for Rotorcraft Operations including
but not limited to the following.
108
1.
41 CFR 109-38.52 Aircraft Management
2.
41 CFR 109-38.54 Official Use of Motor Vehicles and Aircraft
3.
49 CFR 830 National Safety Transportation Board Rule 830
SAFETY PLAN FOR HELICOPTER LIFTS
1.
Name, address, and phone of organization requesting charter operation.
2.
Name, title, address, and phone number of person representing
organization.
3.
Purpose and description of requested charter operation.
4.
Charter operator's name, address, phone number, and FAA Air
Carrier/Commercial Operator Certificate (ACCO) Number.
5.
Type of aircraft, by manufacturer, model/type, and year of
manufacture.
6.
Aircraft Registration Number.
7.
Copy of Airman's most recent proficiency/qualification check for
required crew members to be used on this charter, FAA Form
8410-1 or equivalent.
8.
DOE O 440.2, Requirements
a.
Is charter aircraft owned or leased? If leased, provide
Lessor's name and address.
b.
Are pilots full-time employees of the operator?
c.
Have pilots logged the prescribed flight time in the aircraft?
d.
Are charter operators and pilots fully certified for the type of
aircraft to be flown?
e.
Does the charter operator have full control over the aircraft
maintenance program?
f.
Is the aircraft fully equipped for instrument flight?
g.
Are pilots and copilots certified for instrument flight?
h.
Does the charter operator have a suitable flight and ground
crew training program for the safe handling of the types of
materials and cargo to be transported?
i.
Does the charter operator have the ability to secure any
necessary exemption from the FAA?
j.
Has the pilot ever been grounded for disciplinary reasons?
109
110
k.
Has the pilot flown this type of mission before?
l.
Minimum altitudes and clearances over structures
m.
Preflight pilot and copilot ground, map, and area reviews
related to charter operation
n.
Security requirement coordination
o.
Emergency landing considerations and planning
p.
Description of any local Notice to Airmen temporary flight
restrictions.
q.
Description of minimum weather requirements, if different from
basic VFR conditions.
Lift Plans - Checklist items for an efficient and well coordinated lift
9 Listing of helicopter picks and their order.
9 Any “I” beams shall have temporary welded cross brace on both sides of the chocker to
prevent the beam from sliding out of the choker when lifted.
9 Materials to be picked should be laid out in an orderly fashion with spacing sufficient to
prevent each pick item from striking any other pick or object and allow safe access for
personnel.
9 Materials should be in same orientation as their planned placement on roof.
9 Areas to be considered for picks must be broom swept and have no items that are not part
of the lift in the area. All extraneous materials must be moved a minimum of 150 feet from
the pick zone.
9 Materials for picks should be marked with the following information:
1. Order of pick number
2. Center of gravity (where applicable)
3. Center of material and choker locations (where applicable)
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Appendix K
Helpful Telephone Numbers (updated)
Note: All numbers begin with area code 816. If calling from within the plant dial last 4 digits only
EMERGENCY
997- 3600
SPILL HOTLINE
997-7745
FACILITY ENGINEERING
997-2611 or 997-2300
CONSTRUCTION SAFETY & HEALTH
Mike Duncan
pager 458-2530
Jon Nelson
pager 458-0277
MEDICAL DEPARTMENT
997-3244
997-5142
997-3200
SAFETY AND HEALTH CONCERN LINE
997-3181
MATERIAL SAFETY DATA SHEETS
997-3181
PATROL (NON EMERGENCY)
997-3601
FIRE DEPARTMENT & HOT WORK PERMITS
997-3711
HAZARDOUS WASTE PICKUP
997-7700
WASTE MANAGEMENT
997-4488
UTILITY LOCATION
MOVING LOAD LIMITS
997-5219 or 997-2203
997-4677
Contact: J. Nelson SH1 Rev. 6 11/06
112
Appendix L
113
114
115
116
117
Appendix M
Construction Qualification Requirements (updated)
Qualification requirements are based on two levels of criteria. All Sellers must safety
prequalify prior to solicitation for Requests for Proposals.
•
Part 1 one is a requirement for all construction contractors.
•
Part 2 is a requirement for any contractor who wishes to perform as a general
contractor at the Kansas City Plant.
PART 1:
All contractors shall be qualified on the basis of past safety record. Contractors shall
supply the following information and meet the Kansas City Plant’s requirements before
being placed on the list of qualified Sellers.
All contractors who pass the qualification process will remain on the list until March 1 of the
following year. At that time, all qualified contractors must update their records to remain
on the qualified list. If you are currently under contract you must also update your part
one. However, you will remain on the bidders list for the duration of your contract. you will
remain on the bidders list for the projects you are currently under contract for.
Prospective contractors must answer the questions on the attached form and submit a
packet containing the following data:
1.
Workers’ Compensation Experience Modifier Rate (EMR) for the past three years.
Include a Letter from your insurance carriers stating EMR rating, current year and
previous two years.
Description: The EMR is the ratio of actual losses in worker’s compensation cases
to the expected losses for a contractor doing the same amount of similar work. An
average EMR value is 1.0. Less than 1.0 indicates a better than average safety
performance.
2.
Number of Occupation Safety and Health Administration (OSHA) Recordable
Injuries per 200,000 man hours worked for the past three years.
Description: OSHA recordable rate equals the (number of recordable incidents X
200,000/manhours worked) and indicates the frequency of accidents. The average
value for construction of all types in 2004 was 6.4. This number will vary for
different trades. Comparisons will be made with the nearest craft being prequalified.
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3.
OSHA Lost Workday Away Rate per 200,000 man hours for the past three years.
Description: Lost Workday Away Rate equals the (number of lost workday cases x
200,000/man hours) and indicates the frequency of serious incidents. The average
value for construction of all types in 2004 was 2.4. This number will also be
compared within a particular trade.
4. Safety involvement
Submit recent representative documentation demonstrating employee involvement in
any two of the following safety processes: 1) safety committee
charter/statements/minutes, 2) attendance logs of tool box safety meetings, 3) safety
inspection checklists, 4) injury investigation reports and how lessons learned are
communicated with workers, 5) worker awareness of your stop work policy, 6)
workers submitting and resolving safety concerns, and 7) examples of safety
recognition activities/events for workers.
5. Employee training
Hazard communication training and other OSHA mandated training and/or
certification. Provide documentation verifying your employees have completed
training.
6. Include in your packet:
•
•
•
•
•
•
Completed form
Copy of current year and previous two years OSHA report log. (OSHA 300
form)
Letter from your insurance carrier stating EMR rating for current year and
previous two years
Safety involvement documentation
Employee OSHA mandated training documentation
If you are applying to be a general contractor, you must submit samples of
the following items in Part 2 for the current year
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PART 2:
General Contractors shall provide written documentation with examples validating
their company has a comprehensive safety program with the following:
1. Seller management leadership and employee participation
a. Documented program that defines the roles and responsibilities of
managers, supervisors and employees in their company safety program.
b. Provide examples of documentation that show hazard evaluation and
assessment. (Job Hazard Analysis)
2. Jobsite safety inspections
Provide examples of frequent and regular inspections of the workplace, materials,
and equipment made by competent persons designated by the employer.
3. OSHA mandated programs
Provide evidence of comprehensive written safety and health programs as required
by OSHA standards. Examples include: hazard communications, respirator
protection and confined space entry.
III.
SAFETY EVALUATION
The pre-qualification data submitted will be used to select contractors to be included on the
list of qualified contractors. You will be notified promptly if your safety prequalification
packet is accepted or rejected. Once your packet is accepted it will be kept on file for
future construction bid requests. Annually we will request updates to your file.
IV.
MAIL
Submit your packets for evaluation to:
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Honeywell FM&T
Attn: Construction Safety
SH1-OD48
P.O. Box 419159
Kansas City, MO 64141-6159
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Appendix N
Activity Hazard Analysis
See OSHA 3071 - 2002 (Revised) “Job Hazard Analysis” for guidance
Job Description:
Date:
Job Location:
Analysis performed by:
Required Inspection & Permits:
Equipment:
Daily Hazard Analysis
Hard Hat, Eye Protection w/sideshields
Vehicle Safety Inspections (form 3018)
Job Specific PPE: Gloves, respirators, etc.
Job Specific Permits – Waste handling; Hot work;
Life Safety, Excavation & Utility Location; Penetration
Checklist, Construction Safe Work Permit
Task Description
Emergency Equip. (eyewash, fire ext, first aid kit)
Air Quality Equipment. (fans, monitors, dust control,
respirators)
Hazard Description
Hazard Controls
Site Preparation
Construction Work Zone Hazards
1. Place area barricades
2. Post Control signs at barricades
Site Preparation
Tripping Hazards
Egress / Life Safety
Egress Limitations
Vehicle / Forklifts
Vehicle / Pedestrian Accident
Tools
Tool Handling Hazard
Floor / Concrete Thickness
Dropped equipment through voids
Material Handling
Dropped loads
Material Handling
Strains, cuts
Soil Excavation
Soil Contamination
Job Completion
Environmental Controls
1. Remove, guard or control
hazards
2. Place trash containers
1. Review and use Life Safety
Aisle/Exit Impairment Permit
1. Establish Traffic Patterns
2. Set barricades and crosswalk
zones
1. Inspect tools for safe condition
and correct usage
2. Use appropriate PPE
1. Identify load limits and floor
thickness in work area
2. Coordinate with Buyer
Representative as needed
1. Barricade lift zone
2. Secure loads with safety lines,
control with tether
3. Inspect rigging connections
4. stabilize load
1. Use cut-resistant gloves
2. Use team lift technique
3. Follow proper lifting procedures
1. Check pre-work documents
2. Use appropriate PPE
3. Establish environmental controls
4. Follow site PPE and other safety
requirements
1. Store Waste drums at transfer
location
2. Complete and submit waste
permit
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Appendix O
Daily Hazard Analysis
Job Description:___________________________________Day/Date:_____________________
Job Location:___________________________________________________________________
Analysis performed by:___________________________________________________________
Activities Requiring a CSWP
Competent
Person
Required?
Permits
Yes
Job Hazards
Points of Control
No
Confined Spaces
Slips, Trips, Falls from all
levels
Surface condition? Floors,
Platforms, roof.
Masonry walls >8ft
Struck by / Struck against
Moving vehicles, falling objects /
materials
Caught in / between
Cave-ins, unguarded machinery /
equipment
Electrical shock, arc
Power lines, power tools / cords,
temp. wiring
Scaffold
Yes
Steel Erection
Helicopter Lifts
Yes
Cuts, abrasions,
punctures
Sharp edges, cutting devices, sharp
objects
Cranes
Yes
Foreign body
Dusts, airborne materials
Critical/Unusual Lifts
Strains
Lifting / moving materials
equipment, tools
Shoring
Hearing
Operating machinery, equipment, &
tools
Temperature extremes
Contact or environmental
Painting
Chemical exposure
Systems, chemicals stored &
working MSDS available
Demo – Special Liquid/Gases
Tool usage
Correct tool, proper condition,
training
Unique Tasks
Special training for task
Other Activities
Excavations
Yes
Abrasive Blasting
Minimal PPE
Hard Hat
Foot
Eye protection
Weather gear
Power Actuated Equip.
Hearing
Respirator
Energized Electrical Work
Hand
Chemical Protective
clothing
Radiation source usage
Flammable Gases
Other_______________________________________________
Demolition work
Site Hazards not covered above
Point of Control
1. __________________________________________
1. ___________________________________________
_
2. __________________________________________
3. __________________________________________
_
2. ___________________________________________
_
3. ___________________________________________
_
Signatures
Foreman
1) Define scope of work
Worker
2) Analyze Hazards
3) Develop & Implement Controls
Worker
4) Perform Work
5) Feedback & Improvement
Rev. 2/23/07
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Appendix P
Safety Professional Responsibilities (updated)
The Seller’s Safety Professional shall provide safety oversight at the Buyer’s facility as
required based on the construction workload and level of risk to Seller’s personnel related
to work being performed. Buyer’s expectation is that the Seller’s Safety Professional shall
manage the Seller's safety program and sustain a level of effort to include:
1) Ensure safety requirements and responsibilities are achieved.
2) Improve the Seller's safety performance on the Buyer's site. The Safety Professional
shall be competent within Environmental, Health, and Safety engineering, practices, and
codes. The Safety Professional shall be solely dedicated to this purpose and not work
other duties congruent to this assignment while on the Buyer's site. If the Seller’s Safety
Professional is required to perform work to support assigned duties and responsibilities for
KCP project off site, Seller shall obtain approval from the Buyer’s representative prior to
this work being executed. Seller shall administer their Safety Professional resource to
maximize availability of sustaining off shift and weekend work activities.
Seller’s Safety Professionals and any additional staff must submit a current resume to
KCP’s Safety Department for review. The candidates’ credentials shall be reviewed and
approved prior to the Safety Professional assuming duties and responsibilities of Seller.
Kansas City Plant minimum requirements for construction safety professional:
1.
Safety Professional shall have one or more of the following certifications
• Associate Safety Professional (ASP)
• Certified Safety Professional (CSP)
• Certified Industrial Hygienist (CIH)
• Occupational Safety & Health Technician (OHST)
• If the candidate does not have one of the certifications listed above a current
resume must be submitted to KCP ES&H Management for approval.
2. Additionally, the safety professional must hold the following:
• OSHA 10 hour construction safety certification card.
• Two years minimum hands-on experience in construction safety.
• Specialty safety certification depending on contractor (40-hour haz-woper, asbestos
identification, trenching and excavation competent person, scaffold inspection, etc.)
3. The safety professional must be proficient in:
• Producing and presenting construction safety courses.
• Production of Job Hazard Analysis (JHA) for all aspects of construction- related
activities.
• Microsoft Office programs.
• Shall be available to work days, weekends, nights, holidays and shutdowns as
needed.
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The Seller’s Safety Professional shall perform the following duties:
A. Seller’s Safety Professional shall demonstrate that subcontractors comply with Seller’s
safety program, Honeywell FM&T contractual requirements, OSHA and regulatory
requirements.
B. Safety Professional shall develop and manage general contractor KCP project safety
program.
C. Present the KCP’s site-specific lockout/tagout and confined space training.
D. Map Seller’s safety program and job/contract specific safety plans to subs.
E. Safety Professional shall develop Activity Hazard Analysis Form (AHA) based on
work breakdown structure for projects. The completed AHA shall identify:
1. Site hazards and site controls
2. Any additional controls for site hazards needed to protect workers
3. Principle work steps
4. Task hazards, controls, permits, and training associated with the work to be
performed
5. Hazard controls shall:
a. be specific and written so that the worker does not have to look at another
document to identify the control;
b. map to a hazard and principal work step; and
c. be stated simply, e.g. “wear 1000-volt gloves.”
d. Controls identified for the listed hazards shall be reviewed to ensure that
when controls are implemented no new hazards are introduced and that
controls for site hazards adequately protect workers.
Seller’s Safety Professional shall designate qualified persons to complete Hazard
Analysis daily (see example titled “Hazard Analysis/Toolbox Safety Training”).
Seller’s designated qualified person shall review Hazard Analysis and Toolbox Safety
Training form with crafts daily, identifying task-related hazards, controls, permitting
requirements, and validate training associated with the work during site or pre-job
briefing (craft must sign-off on form and form must be posted on job site daily).
Seller’s Safety Professional shall provide oversight for project daily hazard analysis.
Seller’s Safety Professional shall demonstrate field presence during construction
activities ensuring that supervisors / workers apply and implement hazard controls, while
overseeing work activities to ensure compliance with ES&H requirements.
Seller’s Safety Professional shall establish and implement a system for visitor control
and orientation for each job site.
Seller’s Safety Professional shall produce and present safety and health topics at
various ES&H-related meetings.
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Seller’s Safety Professional shall document and manage general contractor and
subcontractor training/qualification records on site, for the following components.
1. Hazard Communications
2.
Lock/Out Tag/Out
3.
Ladder and Stariway Safety
4.
Any Additional OSHA Mandated training
Seller’s Safety Professional shall be a team member on any investigative team assign to
develop root cause analysis related to GC/sub accident/incident on his/her contract.
Seller’s Safety Professional shall track and trend safety observations (good and bad)
and provide analysis in report format quarterly to KCP Buyer representative.
Seller’s Safety Professional shall implement safety oversight program based on worker
observation that tracks incident causal factors to include training/tools/attitude.
Seller’s Safety Professional shall meet monthly with other contractor SP’s and KCP’s
Safety Engineers to share lesson’s learned.
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Appendix Q Penetration Checklist (new)
127
Appendix R
128
129
Appendix S
130
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