Contractor
Site Specific
Orientation
Revision Date: April 12, 2013
1
Disclaimer
• This orientation is intended to
highlight some of the health
and safety rules, programs
and procedures in place and
required by our site.
• It is not all inclusive.
• Critical information is
highlighted in RED.
• To view all aspects of these
programs, please refer to the
Contractor Safety Manual.
2
Disclaimer
• This orientation does not
replace the OSHA required
training provided by the
SWLA Safety Council and by
your company.
• This training only covers our
site specific requirements.
• This does not replace the
dialogue required between
you and the authorized Grace
representative and Grace
custodian.
3
Test
• There will be a
comprehension test
following the training.
• 80% passing grade
• Once passed, an
orientation card will be
issued.
• If failed, have to reschedule
for another day.
4
5
What is VPP?
• Voluntary Protection Program
• Grace – Lake Charles Plant is an
OSHA VPP Star Worksite.
• Designed to recognize and promote
effective safety and health
management.
• Management, labor, and OSHA
establish a cooperative relationship
at a workplace that has implemented
a strong program.
• Contractors will be interviewed by
OSHA during onsite visits to
determine if they understand the VPP
program, know the site safety rules
and follow them.
• VPP participation does not take away
your right to file a complaint with
OSHA.
6
What is RCMS?
• Responsible Care Management
System
• Grace – Lake Charles Plant is a
certified RCMS site.
• Provides the framework and sets
performance expectations for planning,
prioritizing, implementing, measuring,
and reviewing EHSS activities to ensure
continual improvement.
• The system sets forth performance
expectations that address EHSS
hazards and risks, training and
communication, operational control,
goals and target setting, assurance,
compliance management, product
stewardship, and periodic internal
review.
7
Entry and Exit to the
Facility
• All personnel must scan or log in
and out whenever entering or
leaving the site.
• Identification badges must be
visible at all times.
• Contract vehicles must have
company identification (i.e. on the
side, etc) and have a vehicle pass
from security.
• Dress code: No torn work clothes
are allowed or clothes with holes in
them. No sleeveless shirts are
allowed. This is for your own
protection.
8
Entry and Exit to the
Facility
• Required PPE must be worn when
inside the facility.
– Hard Hat
– Safety Glasses
– Hearing Protection
– Steel toed shoes
– NOTE: Certain jobs/areas may
require additional PPE. Refer to the
maintenance job task PPE chart on the
Contractor Safety page of the interlan
or website.
Exceptions include:
– Hard hat and ear plugs not required
in contractor’s compound area or
maintenance shop
• However, ear plugs however would be
required if work being conducted such
as grinding, etc.
9
Entry and Exit to the
Facility
• We are regulated by the US Coast
Guard and the Marine
Transportation Security Act.
• To gain unescorted access
to this facility, you must
possess (and have inside
our fenceline, accessible
within 10 minutes) a valid
TWIC card.
• If you do not have a TWIC
card, you must be escorted
by a Grace representative at
all times.
10
Vehicle Rules
• Operators of vehicles must obey posted
speed limit signs. (10 mph)
• Seat belts must be worn at all times while
in ANY moving vehicle
• Pedestrians always have the right of way.
• Watch for large truck and railroad activity.
• When you park inside the facility, you
must turn off the engine and leave the
keys in the ignition before exiting your
vehicle.
• Do not walk in the area of the RR track
unless you are there doing work. Stay on
the roads to cross the tracks.
• Passengers are not allowed to ride on any
equipment not specifically designed for
such.
• There is to be no passengers riding in the
beds of pick-up trucks unless equipped
with appropriate seats and seatbelts.
11
Parking
• There is designated parking in the
contractor parking lot (Gate 5).
• In the event of a large outage job, the
overflow parking for contractors will be
at the Recreation building parking lot
(Gate 9/9A).
• Only authorized vehicles are allowed
to drive in the plant.
• You are NOT allowed to park in the
unit or on the road, unless actively
unloading equipment. Then you must
move your vehicle to designated area.
• Your Grace representative will direct
you on where authorized vehicles will
be allowed to park inside the plant.
– Contractor compound
– West of Administration Building
– North of HPC plant
12
Tobacco Products
• Smoking is allowed in designated
areas only Cigarette butts must be
thrown in cigarette receptacles, not
trash cans or on the ground! No trash
should be placed in these receptacles!
• Chewing tobacco is allowed in all plant
areas (except HPC), but a spillresistant container (such as a cup with
a napkin) must be used and deposited
in appropriate trash receptacles. Do
not spit directly in the trash can or on
the ground or leave spit cups laying
around.
• Violations will result in the site taking
action to make this a tobacco-free
facility.
13
General Site Rules
• Drinking, eating, storing or preparing
food or beverages for consumption in
any laboratory, maintenance or
process area is prohibited. (NOT
ALLOWED)
• Cameras are not allowed unless
permission is obtained from Grace
Security.
• Cell phones are not allowed in the
plant unless authorized by Grace
Security.
• No unapproved cutting tools allowed.
14
Process Safety Hazards
There are several hazards present at
the GRACE Lake Charles plant.
Chemical/Particulate hazards:
• Acids (Sulfuric, Hydrochloric, Nitric, Phosphoric)
– Skin/eye contact – immediate chemical burn/irritation
– Inhalation – throat irritation, burning, coughing
• Caustic (50%) Solution
– Skin/eye contact – feels slimy, prolonged exposure
causes chemical burn/irritation
– Inhalation – throat irritation, burning, coughing
• Aqua Ammonia (pungent odor)
– Skin/eye contact – chemical burn
– Inhalation – nausea, vomiting, breathing difficulty
• Nickel Nitrate Solution (green color)
– Skin/eye contact – irritation, sensitization
– Inhalation – throat sensitization
15
Process Safety Hazards
Chemical/Particulate hazards cont’d:
• Silica quartz (crystalline silica)
– Found in sand at Silicate Plant
– Inhalation – chronic exposure could cause silicosis
• Natural Gas (found throughout plant)
– Flammable
– Displaces oxygen in air
• Rare Earth Chloride & NORM
• Dust
•
– Inhalation and eye contact hazard
Dusty jobs or high wind conditions warrant goggles or dust
glasses as upgraded PPE
• Steam (300 psi)
– Thermal burns from contact with steam or steam piping
16
Process Safety Hazards
Mechanical hazards include:
• Screw conveyors
• Pinch points
• Belt Filters
• Calciners
• Sprockets & chains
Other hazards include:
• Uneven walking/working surfaces
• Slipping hazards (slurry, media, floc)
• Material draining to ditches (do not
step in ditches)
17
Plant Areas
• The facility is broken down into
different units/areas/plants.
• Each one will be highlighted and the
it’s unique hazards briefly
discussed.
• There are some hazards that are
common among all areas:
– Thermal burns from steam and gasfired equipment
– Dust (wear goggles or dust glasses to
better protect eyes during windy
conditions)
– Natural gas
• Should you have questions,
concerns, or need additional
information, please contact any
Grace representative.
18
Additives (Z14) Plant
Silica Sol (Super D) Plant
DA & Alumina Plants
• Acids
– Sulfuric
– Hydrochloric
– Phosphoric
• Ammonia
• Caustic
• Rare Earth Chloride & NORM
More information on NORM will
follow in a few slides.
19
Additives (Z14) Plant
The Code 550 area which contains
crystallizers (equipment #s: 1210, 1210A
through C, 1214D, 1238F, 1211G through T) are
hazardous due to the
temperature (~220°F) of the
product being boiled inside and
potential for it to boil over.
This area can only be accessed
with permission from the Code
550 A or C operator!
There are signs indicating this, as
well as red chain around the
area.
20
XP Plant
• Acids
– Sulfuric
– Hydrochloric
• Ammonia
• Caustic
• Rare Earth Chloride & NORM
• Hydrogen
The red painted area around the CX100 reactors is a restricted area
due to the potential for hydrogen
accumulation. This is a hot work
permit required area. Equipment in
this area must be intrinsically safe.21
Boilerhouse
•
•
•
•
Water treatment chemicals
Hot water
Steam
300# steam boiler
22
Carcinogens
• There are two materials in the
Grace facility which are known
carcinogens:
– Silica quartz (Silicate Plant)
– Nickel (HPC Plant)
• Silicate plant
– Sand (raw material)
• ~97% quartz (silica quartz)
– Silicate (after furnace)
• amorphous silica (not a health
concern)
23
Silicate Plant
• Sand
– Silica quartz
or crystalline silica
• Soda Ash (caustic soda)
• Hot glass (solid & liquid)
• ~2700ºF furnace
When cleaning this area, air
should not be used. Use
broom or vacuum so as not
to cause silica dust to
become airborne.
24
Silicate Plant
• The silicate furnace is put
together similar to an igloo.
• The inside of the furnace is
2700°F.
• The crown of the furnace
should NOT be walked on.
• Remain on the catwalk at all
times!
The area underneath the furnace and
behind the chill roll is a restricted
25
area and requires operator approval.
Carcinogens cont’d
• HPC (hydroprocessing catalyst)
– Allergy risk (most common)
– Nickel nitrate, liquid (soluble Ni)
• Inhalation of fumes
• Dermal contact
– Nickel carbonate, powder
(insoluble Ni) & Catalyst, nickel
oxide, solid (insoluble Ni)
• Inhalation of dust
• Ingestion
26
HPC Plant
• Acids
– Nitric
– Phosphoric
• Ammonia
• Nickel
• Molybdenum trioxide
The HPC plant is a restricted
area due to the presence of
nickel, which is a known
carcinogen.
27
HPC Hygiene Procedures
Access to HPC and its staging area
are restricted areas.
Coveralls (Tyvek or cloth) are
required when entering any
“Restricted Access Area” of the HPC
plant.
A change room has been provided
for personnel that will exit
“Restricted Access Areas.”
Contract personnel can use the
HPC facilities to clean up after
exiting the “Restricted Access
Areas.”
28
HPC Hygiene Procedures
There are signs designating areas:
• “Clean” areas
• Outside of HPC buliding
• Changeroom & control room
lunchrooms
• Control room
• External stairs
• “Restricted Access” areas
• Exposure to nickel
• Staging area (warehouse) and control
station (by loadout)
• “Transition” area
• Changeroom locker rooms
• Entry to control room (washroom)
• MCC & Elevator
29
• Corridor (breezeway) to control room
Change room - Ground floor
Control room – 5th floor
30
HPC Hygiene Procedures
Entry into a “Clean” Area if you have NOT
been in a “Restricted Access” area:
• Use “clean” pathway
• Elevator or NE stairs to access
control room
• NOTE: You must still vacuum shoes
and wash hands before entering
There is no “clean” pathway to the
operator control station on the ground
floor. You must use the phone in the
downstairs lunchroom to call the operator
control stations for assistance.
31
HPC Hygiene Procedures
To enter a “Restricted Access” area:
• Wear clean disposable (i.e. Tyvek)
coveralls over street clothes
• Enter HPC through NE side (bay door or
door by stairs)
Food, tobacco products, gum or any
other item which is handled and
placed in the mouth is strictly
prohibited within “Restricted Access”
Areas.
32
HPC Hygiene Procedures
Entry into a “Clean Area” from a
“Restricted Access Area” includes
additional administrative controls.
It will be necessary to:
1. Clean equipment (e.g., hats, tool
pouches, etc.),
2. Vacuum coveralls (or remove
disposable coveralls and dispose)
3. Vacuum shoes
4. Wash exposed skin
33
HPC Hygiene Procedures
Disposable coveralls can be altered
(i.e. cut sleeves) as long as they
completely cover street clothes.
They must also remain zipped up.
Disposable coveralls are:
* not allowed in “Clean Areas”
* or off the HPC grounds after they
have been worn in a “Restricted
Access Area”.
34
Other Restricted
Areas
ALL REQUIRE OPERATOR
APPROVAL TO ENTER:
• MCC/IO rooms
• DA Penthouse (high pressure
nozzles)
• Rare Earth Tanks (presence of
NORM)
• High Voltage fenced in areas
(13200V)
• MARSEC areas for security
(security areas, docks, 1040F tank)
• Area under Silica Sol (Super D)
control room (overflow hazard)
35
Asbestos
• There are some areas in the
facility which contain asbestos.
• They include:
– Insulation
– Roofing material
– Transite siding
– Flooring (Maintenance Tool
room)
• In most instances it is
impossible to determine if
insulation is Asbestos by just
looking at it.
36
Asbestos
• If any insulation you come in
contact with is not properly
identified as Asbestos Free
(tagged with blue ID.
Markers), or is suspect, stop
your work and contact the
Environmental Department.
• Proper testing will be
conducted to determine if the
insulation is Asbestos and it
will be properly labeled.
ASBESTOS FREE
37
Lead
• There may be some vessels
which still contain red lead
primer.
• If you are about to blast, cut or
weld (for example) on a vessel
and are unsure if it is lead-free,
please STOP and contact your
Grace representative.
38
Paint Program
• Before any contractor can use
paint in this facility, you must
first contact the Environmental
Department.
• You must first be shown where
to clean up and dispose of
waste paint.
• You will receive hazardous
waste training.
39
NORM
• NORM = Naturally Occurring
Radioactive Material. It occurs
naturally throughout the earth's crust.
• At Grace, NORM is found in Rare
Earth Chloride. The amount of
gamma radiation emitted from NORM
is relatively small and the levels
associated with the rare earth
chloride are generally not a hazard.
• The radiation hazards associated
with NORM are primarily from
inhalation and ingestion of alpha
radiation.
• Radium 226 can concentrate to
significant levels in some process
systems and poses a hazard to
workers handling or performing
maintenance on contaminated
40
equipment.
NORM
• Avoid breathing in NORM
contaminated material that is
distributed into the air.
Wetting the NORM contaminated
material often prevents the material
from becoming airborne.
• Eating, drinking, smoking, or
chewing is not allowed in the
immediate work area around
NORM contaminated material.
• Grace Environmental/Safety
Department must be notified prior
to work on NORM contaminated
equipment to ensure a NORM
qualified person will oversee the
activities to ensure compliance with
state and federal regulations. 41
Hazard
Communication
• Protect Yourself from Chemical
Hazards!
– Be informed. Read the tank label
and/or MSDS. Find out about the
chemicals you might be dealing
with before an emergency
develops.
– Use personal protective equipment
as required by the MSDS.
– Label all containers with the
contents and hazards.
– If you don’t know what you are
dealing with or come across a
substance that is not readily
identifiable, please contact your
supervisor or Grace
representative.
42
How to Find a MSDS
• For more info on any
chemical or material in the
facility:
• From any computer in the
facility, go to the Internet
Explorer icon.
• You will be at the LC
home page.
• Click on the MSDS link.
• Enter the chemical name that
you are searching for.
• Ask for assistance if needed.
43
Plant Color Codes
PIPING:
Fuel Gas Piping
Acid Lines (Un-insulated)
High Temperature (Insulated)
Fire Water Piping
Potable Water Piping
HOSES:
Water/Air ONLY
Chemical
Must use Chicago
coupling safety clips on
all hose connections.
44
Reporting of
Incidents
• Report all:
– Injuries
– Illnesses
– Incidents (Near
Miss & Property
Damage)
IMMEDIATELY
TO YOUR
SUPERVISOR
All incidents and near misses must also
be reported to your Grace site contact or
Grace safety department.
45
Emergency
Procedures
• To report an Emergency:
– Dial 3571, 3555 or 3542 on any
plant phone.
– Radio channel 16 (on all zones)
– State your name, location and
nature of the emergency.
– Remain Calm.
– From all other phones, dial
583-3571, 583-3555 or 583-3542
46
Emergency Alarms
• Emergency Alarms: Siren followed
by verbal announcement indicating
the location and nature of the
Emergency. If the area you are
working in is affected, you shall:
– Evacuate immediately
– Report to designated assembly area
(either evacuation assembly area or
shelter in place location depending on
the nature of emergency)
– Notify your supervisor that you are
there
– Supervisor must notify the Grace
contact with headcount
– Wait for further instructions
47
Emergency Alarms
• General Plant:
– Every Wednesday at Noon,
there is a test of the emergency
alarm system.
• XP Plant:
– In the event of an emergency at
the XP plant (due to the
presence of hydrogen), the XP
emergency alarm will sound and
you must evacuate the XP plant
only.
– There is a test every month of
the XP alarm.
48
Emergency
Procedures
• There are several orange
windsocks throughout the facility.
• In the event of an evacuation or
shelter-in-place:
– To reach the designated assembly
area, travel cross wind, then upwind. Call your contract
coordinator to report your
location.
– Wait until the All-Clear message is
broadcast before returning to the
work area.
– Once back at the work area, ensure
all Permits have been re-instated
before beginning any work.
49
Evacuation
Assembly Areas
There are five evacuation
assembly areas in the
Grace facility.
These include:
-the construction guard gate
-the main gate (parking lot)
-the Lagoon area
-the southwest corner of HPC
-west side of the plant by the
water tower
50
51
Shelter-in-Place
Assembly Areas
There are many shelter-in-place
assembly areas in the Grace
facility.
These include:
-all operating unit control rooms
-Grace maintenance lunchroom,
warehouse and offices
-Front and Back guard gate
-Contractors trailers
-Loaders station
-Admin accounting area
-Grace laboratory
This does NOT include MCC rooms
and I/O rooms.
52
Emergency Drills
Grace periodically conducts
drills for shelter in place
and evacuation scenarios.
These drills are conducted via
plant radios. When
operators exit the area (for
evacuation drills),
contractors will be notified
on their way out when
possible.
53
Pre-Task Hazard Analysis
•Job Safety Analysis (JSA):
–A hazard analysis must be done prior to each
job
–A copy of the completed JSA should be
reviewed with the operator, attached to and
turned in with the work permit/order daily.
–One of the most effective tools that can be
used, if used properly, in the reduction of work
place incidents and injuries.
–Look for items including, but not limited to:
•Pinch Points
•Line of Fire/Eyes on Work Path
•Rotating Equipment
•Hot/Cold surfaces or materials
•Chemical Contact
•Sharp Objects/Splinters
•Proper Energy State (ZERO Energy)
•Path of Travel
•PPE and tool selection, condition and use
54
•Body position
Protecting Employees
•Eliminate the Hazard
•Separate Employees From Hazards
•Separate Hazards from Employees
•Select Work Processes to Protect
Employees
•Maintain good housekeeping
Each employee performing work must know
and understand the safety and health
requirements that apply to the work they are
assigned to perform. Employees who receive
assignments that they do not understand, have
an obligation to request additional information
and further clarification before they commence
55
their work activities.
Personal Protective
Equipment
Employees are responsible for
following all provisions of this program
and related procedures. They are
expected to wear PPE when and
where it is required.
AGAIN:
•Minimum PPE to enter facility:
–Hard Hat
–Safety Glasses
–Steel toed shoes
–Hearing Protection
Some maintenance tasks require additional
PPE. Refer to the maintenance PPE chart on56
the interlan and website.
Personal Protective
Equipment
• Head Protection:
– Head Protection must meet current ANSI
Standards.
– Hard Hats must not be altered in any way
– Brim must be worn facing the front; except
when welding and performing rigging
activities (special permission from your
contract coordinator must be granted).
• Eye/Face Protection:
– Protective eyewear must meet ANSI Z87.1
Standards. This includes Prescription
Eyewear.
– Tinted eyewear is not allowed after dusk
and before sunrise, nor in any enclosed
areas, or covered buildings (unless
specified by activity).
– Additional Eye/Face Protection is required for
some tasks (e.g.. Goggles, Face shields).
57
Personal Protective
Equipment
• Hearing Protection:
– Approved hearing protection must be worn in
all process areas of the facility (past the
maintenance shop and admin building) and
when grinding.
• Foot Protection:
– Sturdy leather footwear meeting ASTM
standards (Steel Toe) must be worn at all
times
– Periodic checks will be made to ensure
compliance.
• Body Protection (Clothing):
– Long pants, suitable for work, must be worn
at all times in the plant.
– Shirts may not be of the sleeveless type.
– The HPC unit requires additional clothing
protection as discussed in previous slides.
58
Personal Protective
Equipment
•
•
Respiratory Protection :
– Where respiratory hazards are encountered,
approved respirators must be worn.
– Employees must be medically cleared to wear a
respirator.
– A current fit test must be obtained.
– The wearer must be clean shaven in the sealing
area.
– Respirators must be chosen for the specific
hazard to be encountered.
– Users of respirators must be properly trained.
Hand Protection :
– Where hazards are encountered, appropriate
hand protection (i.e. gloves) must be worn.
– Canvas/Cloth gloves - wood, abrasives, rough
surfaces etc.
– Leather gloves - hot and cold surfaces, sharp
metals (limited protection), jagged wires, sparks
from welding or cutting torches
– Chemical Resistant gloves - liquid and powdery
substances
– Cut resistant gloves must be worn when using
cutting tools.
– Appropriate gloves must be worn when
59
performing any type of work.
Personal Protective
Equipment
• Fall Protection:
– Employees are required to utilize fall
protective equipment any time work
is required to be performed greater
than 6-feet above a lower surface
and exposed to a fall.
– On incomplete (Yellow Tag)
scaffolds, the employee must wear a
harness and the lanyard must be
secured to a proper anchorage point
when over 6-feet.
– Lanyards with shock absorbers and
double locking hooks are required.
– Fall protection chokers “cheaters”
are to be used only when
necessary. They are not meant to
be used for convenience to gain
60
access to work areas.
Fall Protection
WE HAVE ZERO TOLERANCE FOR
NOT UTILIZING FALL PROTECTION
WHEN REQUIRED
•
The attachment point of the
body harness shall be located
in the center of the wearer's
back near shoulder level, or
above the wearer's head.
•
Personal fall arrest systems
shall be inspected prior to each
use for wear, damage and
other deterioration, and
defective components shall be
removed from service.
•
When attaching the lanyard,
the attachment point should be
at or above the shoulder.
In the event that the wearer feels his/her safety harness,
lanyard, or lifeline is not in perfect condition, it shall be
61
reported immediately for inspection.
Tools
•
•
•
•
•
•
Keep cutting tools sharp. Pin knives and
pocket knives are not allowed. All cutting
tools must be safety cutters (spring-loaded
or retractable blades, concealed blades
and/or blade guards), unless approved by
the Safety Department.
Use the right tools for the job.
Do not use chisels with “mushroom”
heads, cracked or splintered tools, or pipe
wrenches with smooth jaws.
Examine all tools before use. Turn in
defective tools to your toolroom and tag
“Do Not Use”.
Do not drop tools to another level.
When using an open end or box wrench,
make certain it is the proper size for the
nut. Also make sure that the jaws of the
pipe wrench have a solid grip on the pipe.
Always pull the wrench towards you
whenever possible, to prevent smashed
62
fingers, or slipping or falling forward due
to momentum.
Barricading
Requirements
•
•
•
•
•
•
•
•
Floor holes and openings shall be covered and
labeled with “HOLE” or “COVER” to provide
warning of the hazard. Covers located in roadways
and vehicular aisles have to be capable, without
failure, of supporting at least twice the maximum
axle load of the largest vehicle expected to cross
over the cover.
Work crews are responsible for erecting barricades
for their work activity.
Barricades are to be kept at least 2 ft from an
excavation
Appropriate barricades, including barricade tape will
be used based on the hazards associated with the
work.
Barricades are to be maintained and removed when
work is completed.
Unauthorized personnel are not allowed to enter
“Red” barricaded areas without permission from
operator, or maintenance or contact supervisor.
Road Barricades, signs, detours or other traffic
control systems must be approved by Grace
Security.
63
All employees must obey posted barricades.
Types of Barricading
• Radiation:
– DO NOT ENTER
– No one except the radiographic
employees will be allowed entry into the
barricaded area while the special
colored tape is up.
• Red - DANGER:
– DO NOT ENTER WITHOUT
PERMISSION
– Give notice of areas where the hazard is
not readily apparent
– Hazards
could
possibly
be
life
threatening or disabling.
• Yellow - CAUTION:
– Enter AFTER reviewing hazard(s)
– Give notice of hazards that can be seen
by personnel coming into the area
– hazards are not to be considered life
64
threatening or disabling
Barricading
Requirements
•Do not overlap different colored
barricading.
•Barricade Tags:
–A tag must be placed on ALL barricades.
–The tag must identify:
–Company
–Name of person installing barricade
–Date
–Nature of hazard(s)
Red – Tags for DANGER barricade
tape must be updated daily.
65
Railroad
• Be alert at all times for a moving
train.
• Clearances for scaffolds, or other
temporary structures, from
railroad tracks is 8-feet 6-inches
from the centerline of the
track. To erect any scaffold
closer than this clearance
requires permission from a
loader supervisor and adequate
communication to the
loader/unloader group.
66
Scaffold Safety
General Safety Guidelines
a. Inspect all scaffolds before using. Never
use any scaffold that is damaged or
defective in any way.
b. Scaffolds must be erected in accordance
with design and/or manufacturers’
recommendations.
c. All scaffolds must be erected, dismantled
and/or altered under the supervision of a
“Competent Person”.
d. Do not abuse or misuse the scaffold
equipment. Never use equipment for
purposes or in ways for which it was not
intended.
e. Erected scaffolds should be continually
inspected by users to be sure that they are
maintained in safe condition. Report any67
unsafe condition to your supervisor.
Scaffold Safety
General Safety Guidelines
f.
Do not work on scaffolds if your physical
condition is such that you feel dizzy or
unsteady in any way.
g.
Do not get on a scaffold which is not tagged.
Be sure to read each scaffold tag before
getting on the scaffold.
h.
Remember this - Even though all scaffolds
may have the appropriate tag, each scaffold
must be visually inspected before any
workers climb on to the scaffold to perform
work.
i.
Remove all tools/material after job
completion or end of shift.
j.
Never take chances! If in doubt regarding
the safety or use of the scaffold, consult a
scaffold supervisor.
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Scaffold Safety
• Scaffold Tags:
• Red Tag/No Tag – DO NOT
USE: Scaffold is being dismantled,
not completely erected or safe, and
shall not be used by anyone except
scaffold builder.
• Yellow Tag – Incomplete: Scaffold
cannot be fully erected with all
components in place. Tag specifically
cautions user what is not completed.
• Green Tag – Complete:
Scaffold is complete with handrails,
midrails, toeboards, and decking.
Green Tagged Scaffolds are
preferred at Grace.
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Maintenance Work
Permits/Orders
•
•
A work permit or work order must be obtained for all
maintenance work done at the Lake Charles plant.
The custodian (Grace personnel) and all craftsmen
(authorized workers) shall jointly complete the work
order and JSA at the job site. They shall:
– Achieve a mutual understanding of the scope of work to
be performed.
– Physically inspect the jobsite.
– Physically identify the equipment to be worked.
– Assure the equipment has been properly prepared
– Perform oxygen content, combustible gas (LEL), and
toxic gas testing, if applicable
– Determine potential hazards and/or precautions that
need to be taken.
– Locate the nearest shower/eyewash station if applicable.
– Discuss the safe evacuation of the job site.
– Identify and discuss established Grace procedures that
may relate to the job.
– Assure a mutual understanding of the preparations,
hazards, and special procedures.
– Sign on the work permit
•
The work order shall remain in the control room until
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the completion of the work.
Maintenance Work
Permits/Orders
Requirements Upon Completion of Work:
• Ensure that all parties have completed and/or
suspended their work activity and are aware
that the Safe Work Permit is being canceled
or has expired.
• Notify the custodian (Grace personnel) that
the work has been stopped, completed or
suspended.
• Complete final steps of lockout/tagout.
• Ensure the jobsite is being left in a safe and
clean manner.
• Sign off the work permit
• Remove the original work order from the
control room and return the form to the
contractor or Grace representative office.
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Lock Out / Tag Out
(LOTO)
• Preparing the Equipment for
Shut Down and Maintenance:
– Know the types and amount of
energy you could encounter
– Understand how the energy can be
released and controlled
– Obtain information from an
authorized Grace representative
regarding the sequence of energy
isolation required to safely deenergize the system
– Contact your supervisor if you
should encounter problems or if
you have questions
– On an on-going plant outage,
you can leave your locks on, but
the tags must be updated daily
and the equipment ‘tried’ to
verify zero energy.
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Lock Out / Tag Out
(LOTO)
Energy Isolation Tags:
• Danger-Do Not Operate tags:
– All installed locks must be accompanied by a
"Danger-Do Not Operate" tag properly filled
out indicating:
• Reason for lock out.
• Date of lock out.
• Signature of installer (clear and legible)
– The Danger Do Not Operate tags are red
and white in color with “Danger Do Not
Operate” written in red.
• Blind Point tags:
– Any maintenance work requiring a blind
flange to be installed, (such as confined
space) must be accompanied by a "Blind
Point" tag properly filled out indicating:
• Signature of Craftsman
• Signature of Custodian
• Date of installation
– Blind point tags are yellow in color with black
stripes and “Blind Point” written in red.
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Lock Out / Tag Out
(LOTO)
Energy Isolation Tags:
• Job Incomplete tags:
– A tag placed on a lockout device that notifies
affected personnel that a job is incomplete.
This tag will be used when maintenance on a
system is not completed before shift change,
and a decision has been made that
maintenance will resume at a later date.
– When the Maintenance employee or
authorized worker resumes work on the job,
he must re-lock, tag and try the equipment
using the same procedure and then remove
the job incomplete tag.
– Any incomplete maintenance work requiring
“Job Incomplete Tag” must be filled out
properly indicating the following:
• Signature of Craftsman
• Date of installation
– Job incomplete tags are red in color with
“Job Incomplete” written in yellow.
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Lock Out / Tag Out
(LOTO)
Lock, Tag and Try Data Sheets:
• Equipment-specific list to be referenced by the
Custodian and Authorized workers which is a
guide to help identify equipment to be locked out
so as to achieve zero energy state before any
maintenance work can begin. The purpose of
the Lock - Tag and Try data sheets is to provide
the Custodian and persons performing
maintenance work with the information required
to identify all isolation points for energy sources.
Also, to provide a list of sequential steps for the
following:
– Shutting down the equipment.
– Installing energy isolating devices and
locks/tags.
– Releasing stored energy.
– Removing energy isolating devices after
completion of maintenance.
– Inspecting equipment before re-energizing.
– Re-energizing equipment.
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– Responsibilities for each of the above.
Lock Out / Tag Out
(LOTO)
Lock, Tag and Try Data Sheets:
• LOTO data sheets identify ALL steps
required to render equipment to total
zero energy state.
• It is recognized that some maintenance
tasks will not require that equipment be
rendered to zero energy state. Some
tasks cannot be performed if equipment
is rendered to total zero energy state.
• The custodian and authorized workers
are required to ascertain which isolating
devices identified on the LOTO data
sheet will require lockout.
• ALL ENERGY WHICH COULD CAUSE
INJURY IF INADVERTENT START-UP
OR ACTIVATION WERE TO OCCUR
MUST BE LOCKED OUT!
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Lock Out / Tag Out
(LOTO)
Working within ten (10) feet of unguarded,
energized equipment
• Any person who will be required to work within
ten (10) feet of an unguarded, energized piece
of moving, rotating, or actuating equipment
(including, but not limited to dampers, shafts,
calciner trunions/tires, dissolver,
sprockets/chains, fans, etc) must either:
• 1.) Lockout out the equipment and verify zero
energy state prior to working within the ten
(10) foot minimum clearance; or
• 2.) Adequately guard the moving, rotating or
actuating equipment for protection from
hazards such as those created by point of
operation, ingoing nip points and rotating
parts; or
• 3.) Obtain an approved Management of
Change (as outlined in the Management of
Change Procedure), which lists additional
safeguards required to work within the ten (10)
foot clearance from the unguarded, energized
piece of moving, rotating, or actuating
equipment.
77
ARC Flash Protection
NFPA 70E Standard for
Electrical Safety:
• When resetting breakers or
locking out equipment, you are
in hazard risk category 0,
which REQUIRES the following
PPE:
– Untreated Natural Fiber (cotton)
long sleeved shirt
• Electrical work requires a
higher level of protection. See
a Grace Safety or Maintenance
supervisor for more details. 78
Line Breaking
Procedure covers:
1. breaking open, cutting,
burning, welding, and brazing
on Natural Gas pipelines
2. breaking lines containing
Hazardous Chemicals
3. breaking all other lines not
mentioned above to ensure
their safety and the safety of
fellow employees.
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Line Breaking
Hazardous chemical lines:
• Barricade perimeter
• Wear PPE: Wrap-around face shields
with visor must be worn in addition to
safety glasses – or regular face shield
with goggles – hard hat, earplugs, acid
suit (green), rubber gloves, and steel
toed rubber boots
• At a minimum, two Qualified
Authorized Workers shall be assigned
to any job where a Hazardous
Chemical line is to be opened.
Qualified authorized workers are
required to wear the same level of PPE
as the person performing the task
• A Safety Watch will be assigned for 80
high traffic/busy areas
Line Breaking
• After initial line break for hazardous
chemicals,
• (1) If the break is below eye level,
employees should wear chemical
gloves when working on or handling
piping, and
• (2) if the break is at or above eye
level, employees should wear
chemical gloves and wrap around
face shield with visor and safety
glasses (or regular face shield with
goggles) when working on or
handling piping.
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Line Breaking
• OSHA regulations and Grace Lake
Charles allow working behind a
single block valve on Hazardous
Chemicals.
• If working behind a single block
valve, it must be verified that the
single block is holding.
• Note: A line behind a single block
must be pressurized to determine
if the block is holding. Work can’t
continue until verified. A check
valve CANNOT be used as an
energy isolation valve.
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Line Breaking
Natural Gas lines:
• Barricade perimeter
• Wear PPE: Face shields with visor
must be worn in addition to safety
glasses, hard hat, earplugs and longsleeved cotton shirts to protect against
burns should gas combust
• At a minimum, two Qualified
Authorized Workers shall be assigned
to any job where a Natural gas line is
to be opened. Qualified authorized
workers are required to wear the same
level of PPE as the person performing
the task
• A Safety Watch will be assigned for
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high traffic/busy areas
Confined Space
Entry
• A "Confined Space Work Permit" must be
obtained before ANYONE can enter a
Permit Required Confined Space (PRCS).
The proper permit will be issued by a
trained, authorized Grace representative.
• Contract company will be required to
provide a trained, competent hole watch for
each PRCS job.
• The permit issuer shall review the permit
with the Entry Supervisor to ensure that both
are in agreement that all provisions for safe
entry into the permit space have been met
prior to "SIGN ON". This permit will be valid
for ONE normal shift only. On jobs requiring
more than one single shift, a new properly
filled out permit must be obtained at the
beginning of the next shift or when there is a
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complete change of entry workers.
Confined Space
Entry
• Any totally enclosed temporary shelter that
is constructed directly adjacent to and
adjoining the confined space opening, shall
be considered as an extension of the
confined space due to the possibility of a
build-up of a hazardous atmosphere within
the shelter.
• When applicable the ambient air
temperature in the confined space should be
tested. Permissible entry air temperature
must be =/< 100 degrees. If the
temperature is outside the permissible
range, safety precautions may be stipulated
on the permit for the protection of entrants
who will be working in these environments
with approval from the safety department.
85
Confined Space
Entry
Atmospheric Testing:
• Before any employee can enter a permit
required confined space (PRCS), the
internal atmosphere must be tested with
a calibrated, direct reading instrument for
oxygen, flammability, and if required,
toxicity levels.
• When the confined space has not been
occupied for ONE hour or longer,
atmospheric testing must be repeated for
entry.
• Any Entrant and/or their authorized
representative shall be allowed to
observe any/all atmospheric testing if
requested.
• Continuous atmospheric monitoring
(LEL/O2/CO) must be conducted during
the duration of the work inside the
confined space, and MUST be located
at the level of the worker unless
approved by the Safety Department. 86
Confined Space
Entry
Introducing a hazardous atmosphere:
• All jobs where it is necessary to use toxic or
flammable chemicals in a permit space (i.e.
glues, thinners, cleaners, solvents, etc.) or
where conducting hot work within a confined
space on stainless steel or exotic metal,
entrants will be required to don supplied air
while inside the confined space.
• In addition, a bottle watch is required for the
supplied air system.
87
Hot Work
Requirements
• Hot work permits are required for all
electric or gas welding, riveting, cutting,
brazing, or similar flame or sparkproducing operations.
• Approved fire extinguishers must be
readily available.
• A qualified Fire Watch will be required for
some hot work. This will be noted on the
permit.
• Welding/Burning equipment must be
properly maintained.
• The hot work permit must be displayed in
a conspicuous area during and following
the work to be performed.
• A new permit must be issued if there is a
break in the work of one-hour or longer in
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duration.
Hot Work
Requirements
Fire Watch Required when:
• Hot Work is performed in locations where
other than a minor fire might develop, or
any of the following conditions exist:
• combustible material, in building
construction or contents, closer than 35
feet to the point of operation,
• combustibles are more than 35 feet away
but are easily ignited by sparks,
• wall or floor openings within a 35 feet
radius of exposed combustible material in
adjacent areas including concealed spaces
in walls or floors,
• combustible materials are adjacent to the
opposite side of metal partitions, walls,
ceilings, or roofs and are likely to be
ignited by conduction or radiation
• CX100 Reactors are reacting and the hot
work will be performed around the 1612,89A,
B, C, D and E XP Reactors.
Portable Ladders
• Inspect ladders before each used.
• Ladders must have verification of
current inspection.
• Must use non-conductive ladder
(i.e. fiberglass).
• Maintain the 4:1 ratio when
working off of an extension or
straight run ladder.
• Extension ladders must be
positioned so that there is at least
a 3 section overlap.
• Extension ladders must be
secured (tied off) at the top or held
by another employee at the
bottom.
90
• 3-point contact must be
maintained when climbing ladders.
Mobile Equipment
• All equipment operators must have in their
possession, an up to date certification card
• Daily inspections are required (per each
shift)
• Operators must operate the equipment in
accordance with the manufacturers
instructions
• All traffic rules must be obeyed
• Seatbelts must be worn
• Red barricading must be used when
making overhead lifts
91
Electrical Tools and
Cords
• All electrical tools and cords must be
inspected by the user prior to use.
• Defective tools and cords must be
tagged “Do Not Use” and turned in to
the appropriate person.
• Electrical tools must have verification
of a current inspection.
• Electrical tools must be used in
conjunction with a Ground Fault
Circuit Interrupter (GFCI).
• Electrical cords must be routed
overhead where possible, and
secured with a non-conductive
material.
• Do not remove ground prong from
plugs.
92
Compressed Gas
Cylinders
• Cylinders must be maintained in an
upright position.
• Protective caps must remain in
place unless in use.
• Gauges must be removed when
not in use.
• Cylinders must be secured with a
non-combustible material like a
chain (no rope).
• Backflow preventors must be used
on torches and gauges.
93
Critical Life Safety
Policy #418
• Purpose to promote health and
welfare of Company personnel, by
focusing attention on safety
procedures that are critical to
preventing life altering and other
serious injuries at the workplace.
• The policy affirms Grace’s
commitment to provide training with
regard to these procedures, and
clarifies the implications to
employees who do not follow the
procedures.
• The Lake Charles management
also applies this policy to
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contractors.
Critical Life Safety
Policy #418
Under this policy, the following listed violations will be
regarded as intolerable, and will be subject to the most
severe discipline permitted by law and local agreement, up
to and including termination of employment to any trained
employee who commits any such violation
• Lockout/tagout violation
– Working on energized equipment without a valid permit,
unless allowed under partial or total exemption
– Failure to adhere to the conditions of the permit
• Line Breaking with hazardous material or high pressure
violation
– Conducting line breaking/securing work without a valid
permit
– Failure to adhere to the conditions of the permit
• Confined Space Entry violation
– Entry into a permit required confined space without
authorization and a valid permit
– Failure to adhere to the conditions of the permit
• Hot Work (including cutting and welding) violation
– Conducting hot work without a valid permit
– Failure to adhere to the conditions of the permit
• Work at heights (Fall protection) violation
– Failure to use established fall protection when working 6
95
feet or more above an adjacent lower level on a surface that
has an unprotected side or edge
Questions?
• For more information or to
answer your questions,
please contact your
supervisor or your GRACE
contact.
GRACE
1800 Davison Road
Sulphur, LA 70663
337-583-2611
96
Take Test Now
• Do not write on test sheet,
only answer sheet
• Only one correct answer per
question
• Print Name in box
• ID number is Safety Council
Card Number
• Fill in completely the correct
response circle
• GOOD LUCK!
80% passing grade required
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