ENVIRONMENTAL HEALTH &  SAFETY HANDBOOK

Overview 

ARCOR’s environmental, health and safety (EHS) goal is to achieve and Incident Free Workplace.  An incident is an event that causes or has the potential to cause harm to people or the environment, or damage to equipment or the facility.  An incident can also be an event that violates or has the potential to violate an ARCOR EHS internal policy, standard , procedure or applicable EHS government or community requirement.  In order to prevent incidents, we must all work actively to identify, evaluate, anticipate, investigate and control the root causes of workplace hazards.

The causes of incidents fall into two broad categories:  Unsafe conditions and unsafe acts.  Unsafe conditions may exist in the condition of tools and equipment, work stations, job process or the environment (i.e. unguarded machinery, improperly stacked material, etc.).  Unsafe acts may be the result of lack of employee training or understanding, poor attitudes toward EHS, failure to follow set procedures or guidelines, or failure to be fit for duty (i.e. poor physical condition, being under the influence of some form of intoxicant, or being preoccupied with matters outside the workplace).

This handbook is an attempt to condense more specific, sometimes more stringent programs into a single document which will promote contractor and/or employee understanding of safe work requirements.  This document in itself is not able to cover every aspect of every job in detail.  The omission of any rules from this document does not free the contractor and/or employee from responsibility.  If at any time you are unsure of how to do a job safety, it is your responsibility to ask your immediate supervisor for instruction.  Always be alert for hazards by asking yourself “What if the unexpected happens.”

Value

We will work safely in a manner that promotes the health and well-being of the individual and the environment.

Policy

It is ARCOR’s policy to operate in a safe, responsible manner which represents the environment and the health of our employees, our contract employees, our customers and the communities where we operate.  We expect our contract and/or employees to adopt our example.  We will not compromise environmental, health or safety values for profit or production.

Principles

All ARCOR employees and contract employees are expected to understand, promote and assist in the implementation of this policy and the accompanying principles.

* We are all accountable for conforming with EHS Policy.

* We will work diligently to prevent incidents.

* We will practice sound environmental, health and safety management.

* We will comply with all applicable laws, regulations, and permits,  and will develop and employee more restrictive internal standards where necessary to conform with ARCOR®’s EHS Policy.

* We will audit our operations and report findings.

* We will sponsor activities to improve the science of environmental, health and safety protection.

* We will report on our activities.

* We will support sustainable development, the responsible use natural resources and energy conservation.

* We will supply safe and reliable products and Application.

General EHS Information

A. General Rules and Information

1. Report all incidents such as injuries and/or near misses to your supervisor immediately.  All accidents involving personal injury or damage to vehicles, property or product must be reported immediately.

2. Safety Glasses with permanently attached side shields and safety shoes are required to be worn by all employees.  Alternate or additional types of eye and face protection such as chemical goggles or face shields may be required for certain jobs.  Personal Protection Equipment (PPE) maps and signs indicate areas that require safety glasses.   If in doubt, please contact your supervisor.  Hearing protection is required to be worn while in the production & grinding areas of the plant, or when identified as needed (ie. JSA, SPO, etc.).

3.  Do not wear loose fitting clothing, bracelets, and dangling jewelry, and/or long hair longer than shoulder length (unless tied back or worn under a hat (that may get entangled in equipment.  For more information, see your supervisor.

4. Head protection, gloves, arm covers and other personal protective equipment (PPE) are required in specific areas and for specific tasks, throughout ARCOR®.  Adhere to all PPE requirements.

5. “Horseplay” is a cause of many injuries.  This term applies to any prank or practical joke and is prohibited by ARCOR® rules.  Scuffling, horseplay, yelling, loud whistling and practical jokes are forbidden.

6. For most jobs, it is necessary to work with other employees.  Always be aware of their location and what they are doing to avoid injury both to yourself and your work partners.

7. The Lockout/Tagout Procedure shall be followed.  Do not attempt to repair,, clean or clear scrap from any equipment or powered machine unless all energy sources have been turned off and Lockout/Tagout procedures have been followed.

8. Comply with danger and caution signs.  Do not enter any barricaded area unless you are authorized by your supervisor to do so.

9. Do not stand or walk under a suspended load.

10. Enter confined spaces only at the direction of a supervisor in accordance with Engineering Standard 18.1 and the Confined Space Entry Procedures.  Examples are manholes, storage tanks, dust collectors, silos and elevators pits.  Your supervisor can answer questions you have on this procedure.

11. Walk - do not run.  Watch your step.  Used marked aisles and walkways.  use stairs or ladders when going from one elevation to another.

12.  Keep all aisles and exists clear.  Do not block access to fire fighting equipment, fire blankets, electrical panels, switch boxes or utility shut-off valves.  These are identified either by a sign or conspicuous colored painting.

13.  Keep flammable materials an combustibles in approved safety cans with appropriate labels.

14.  Put all scraps and waste materials into proper receptacles.  keep oily an paint covered rags in closed metal containers.

15.  Do not create or contribute to any risk or unsanitary condition.

16. Do not unnecessarily distract the attention of any employee who is working.

17. Possession or consuming of any intoxicating beverages or illegal drugs on the premises is forbidden.  Reporting for work while under the influence of intoxicants or drugs or while suffering form the effects of the same is also forbidden.

18.  Stay clear of any belt conveyors or transfer equipment.  Do not cross over or under such equipment that is in motion or may be put in motion except at crossovers provided (your supervisor will point out such equipment to you).

19.  Operate only the machine or equipment which you are authorized to operate.

20.  Seat belts must be worn at all time by operators of mobile equipment that is equipped with seat belts.

21.  Seat belts must be worn by drivers and passengers of personal or rental vehicles being used for official company business.

22.  Report all hazards, unsafe tools or equipment to your supervisor.

23.  Use fire extinguishing equipment (only if you have been trained at ARCOR®) on fires and/or directed.  Notify the Maintenance Supervisor when fire equipment has been used so it can be Application.

24.  Glass containers (bottles, jars, etc.) and aerosol containers are not to be brought onto the job site.

25.  Do not sue compressed air or gasses to blow PVC powder or dust off any part of your body or clothing.  This practice can lead to serious injury.

26.  Guards on equipment are put on for your safety.  Do not disable or operate equipment without all guards in the proper position.

27. Employees need to follow Safe Job Procedures (JSA’s) when performing their jobs.

28.  Practice safe lifting techniques.  keep the body upright; lift with the leg muscles and not with the back.  Avoid overexertion caused by improper lifting, pulling, pushing or reaching.

29.  Wear hand pads or gloves when handling hot materials, sharp-edged scrap or rough materials on all jobs and as instructed by your supervisor.

30.  Remove nails from barrels, crates and any other places where they might cause accidents.  Dispose of boards with protruding nails.

31.  Keep floors clean.  Oil or grease is especially dangerous on floors near machines, sharp-edged tools or scrape metal.  Spilled powder or resin needs to be cleaned up immediately.

32.  Arrange materials carefully and securely.  Do not pile or place objects or materials near machines or in such a position that they can fall or block passageways.

33. When stacking materials, avoid leaving projecting edges or points.

34.  Suggestions that will help in safe job performance or identify unsafe conditions or practices are needed.  Suggestion can be brought to your supervisor.

35.  All machinery/work areas must be kept clean by the employee. Damaged or defective equipment should be promptly reported to your supervisor.

36.  Never stand skids or similar items on end and lean them against a wall, support post, railing, etc.

37.  Be sure no one could be injured before you start any machinery or operate valves and switches.

38.  Keep out or the areas that are barricaded or marked restricted.  There may be work in process that may cause dangerous conditions to exist.

39.  Check all tools before using them.  inspect for defects and report them to your supervisor.

40.  When lifting always be sure to sue the proper lifting technique.  When possible utilize lifting equipment or obtain help.

41.  Operate only equipment for which you have been trained.  If you are not sure of operating procedures for a piece of equipment that you are required to run, it is your responsibility to inform your supervisor.

42.  Tank tops and shorts are not allowed to be worn while on the job.  Excessively loose clothing should not be worn, as it increases the possibility of becoming caught in moving machinery.

43.  All mobile equipment operators (lift trucks, tuggers, cranes, etc.)  must be trained to operate the equipment.

44. Heat stress can affect anyone.  Environmental conditions which include high temperatures, high humidity, air movement, and personal variables such as work rate, general health and conditioning can affect your body’s ability to deal with high heat..  be aware of your environment; know which factors increase risk.  drink plenty of water all day before you feel thirsty.  Wear appropriate clothing, loose and lightweight.  Stay in shape.  eat light regular meals.  Know your special risk such as age, recent illnesses, high blood pressure, heart disease, allergy medication or diabetes.  Pay attention to warning signs such as not feeling well, weakness, inattention, dizziness, excessive headaches or nausea that can be preliminary stages of heat stress.  Recognize symptoms and seek appropriate care.  Unrecognized and untreated signs can lead to more serious health problems.

For more detailed safety rules refer to:
Department Job Safety Analysis (JSA's)

B.                    Protective Equipment

The terms “employee” and “operator” also refers to any contract employee.

1.         Eye Protection

* All employees and visitors must wear ANSI-approved safety glasses with side shields which meet ABP’s requirements when entering all Plant Operational areas.  Any questions, see your ARCOR® representative.

*  Employees working with chemicals with a potential of splash or spray, must wear a protective face shield or acid splash goggles.

* Operators using saws, grinders, or similar type equipment must wear goggles.

2.         Foot Protection

Employees and visitors are required to wear steel toed safety shoes in the production areas, warehouse and job sites.

3.         Work Clothing

Personal protective apparel such as protective jackets, aprons, arm guards and the correct glove must be worn per individual department rules.

4.         Hearing Protection  (See Hearing Conservation Section)

Hearing protection is required in manufacturing areas and must be worn on jobs designated by the ARCOR® Representative.

5.         Head Protection

Head protection must be worn on job sites are all times.

6.         Respiratory Protection  (See Respiratory Protection Program Section)

When air contaminants are generated by a work process, it is preferable to control them using substitution of a less toxic material or controlling the contaminants using engineering controls.  When this is not feasible respiratory protection may be necessary.  Prior to using a respirator all employees must:

* Be trained in the use and limitations of the respirator.

* Be fit-tested to ensure proper fit of the respirator.

* Have medical clearance to use a respirator.

7.         Hand Protection

Some jobs require the use of gloves.  The type of glove will depend on the task being done.  Check with your ARCOR® supervisor.

C.        Reporting Hazards

Once a hazard is recognized, it must be reported.  reporting hazards is one of the most important ways you can help ensure a safe work place.  Often an employee can spot problems sooner than anyone else because he/she is very familiar with work place conditions.  Once a problems has been identified, take action to eliminate the hazard and if you are unable to do this, report the issue to your supervisor.

D.        Housekeeping

The foundation for a safe, healthy and pleasant work place is good housekeeping.  Each employee is responsible for keeping his/her immediate work area well organized and the floors free of debris and litter.

* Return all tools and equipment to proper storage place after use.

* Keep materials and equipment out of aisles.

* Clean up all spills immediately.

* Place trash and scrap in the proper containers.

* Pick up all trash from floor.

* Restrooms and water coolers are provided for your convenience and comfort.  Please help keep them clean and sanitary.

* Metal scrap containers are for metal scrap only.  never place any other material in these containers.

* Exits must be kept clear at all times.

Hand/Power Tool Safety

Hand tools can make jobs safer, easier and more efficient.  however, if used improperly hand tools can cause serious injuries.  Always use hand tools as they are intended to be used and maintain them properly.

* Inspect your tools daily to ensure they are in proper working condition.  Damaged or defective tools must be tagged-out and reported to your supervisor immediately.

* Hand tools should be carried in a tool box, bag or tool vest.

* Power saws, grinders and other power tools must always have the proper guards in place.

* Portable electric grinders and other power tools must always have the proper guards in place.

* Hand tools should be used for their intended purpose only.  The design capacity of hand tools should not be exceeded by unauthorized attachments.

* Cords and hoses must be kept out of aisles and off stairs and ladders.

* Electric cords must be unplugged and the airline must be deactivated before adjusting or loading electric or pneumatic tools (i.e. nail guns, staplers, drills, etc.).

Compressed Air & Gas Safety

A.        Compressed Air

* Compressed air used for clearing shall not exceed 30 psi of pressure.

* Compressed air MUST NOT be used to dust off clothing or any part of the body or be directed at any person.  Compressed air or foreign bodies may enter the body and cause severe injuries or death.

* Use only hoses and couplings designed to handle compressed air and inspect them before each use.

B.        Compressed Gas Cylinders

* Keep cylinders out of contact with grease, acids, salt, heat and flame.  Do not handle cylinders or apparatus with greasy hands or gloves.  Never use white lead, oil, grease or pipe compound on welding equipment joints.  Oil or grease in the presence of oxygen under pressure can cause an explosion.

*  Do not handle cylinders roughly.  They must be properly fastened before using or moving on a vehicle or hand cart.  Cylinders, full or empty must be secured when standing vertically while in use and/or in storage.

*  While in storage or being transported, cylinders should have the valves shut off and the supplied protective covers in place.

* Never use a cylinder without a suitable reducing valve and regulators.

*  Never interchange oxygen regulators, hose or other appliances with similar equipment for other compressed gases.

* Always crack the valve of oxygen cylinder before connecting the equipment to purge the opening of any foreign material.

* Protect cylinders from accumulation of ice and snow.  If necessary to melt ice from acetylene cylinders, use warm water.

* Oxygen and acetylene (or other fuel gas) cylinders must be separated by at least 20 feet or by a non-combustible barrier at least five (5) feet high, having a ire resistance rating of at least on-half hour.

* Arc welding electrode or ground leads shall not be hung over compressed gas cylinders.

Manual Material Handling

Most back injuries result from improper lifting.  According to the principles of biomechanics, the worst lifting situation occurs when the body is extended over the load; the lower back becomes a fulcrum supporting the weight of the body, plus the weight of the load.  Twisting in this position invites injury.  Keep your back upright to shift the weight on the more powerful leg muscles and reduce the lever effect.

If the load is too heavy, too large of unstable, get help.  Use hoists or lift trucks when possible.

Portable Ladder Safety Rules

* Only trained employees shall use portable ladders.

* For overhead work use the proper type of ladder. Never use make-shift ladders or stand on equipment.

* Ladders are for climbing.  They are not to be used for levering, bracing, scaffolding or any other purpose which might weaken the structure or create an unsafe condition.

* Straight ladders should be equipped with safety shoes and be properly tied-off at the top an blocked at the bottom where possible.

* Straight ladders will be placed at the proper angle.  Place ladder so the base is out on-fourth the vertical distance against which the ladder is leaning.  The top of a ladder which is being used to access to an elevated work area must extend at least three (3) feet beyond the supporting object.

* Always face the ladder when ascending and descending, and always maintain three (3) points of contact with the ladder.  Never carry objects in your hands while climbing a ladder.  Use a rope or other methods to raise and lower tools and materials from heights.

* Do not over reach outside the side rails of a ladder.  Keep your waist inside the side rails of a ladder.

* Do not splice ladders to make them longer.

Mobile Equipment Safety Rules

1. The main responsibility for safe operation of any mobile equipment lies with the operator.  However, pedestrians must be aware of vehicular traffic in their area and be appropriately cautious around mobile equipment.

2.  Only authorized employees who have been trained may operate mobile equipment.

3.  It is the duty of the truck operator at the beginning of each shift to conduct a vehicle pre-use inspection.

4.  The inside speed limit is 4.5 mph, which is a fast walk.  Use extra care in congested areas, when making turns, or on rough floors or pavement.  The outside speed limit is 6.5 mph.

5.  Face the direction that you are traveling.  Never back up without looking to see that it is clear to do so.

6.  When traveling, keep the forks as low as possible.

7.  If line of travel is blocked by workers or pedestrians, slow down or stop if necessary and sound the horn.

8.  Be sure that your truck is properly and carefully loaded.  DO NOT attempt to handle loads beyond the rated capacity of the truck.

9.  Do not allow any person to walk under raised forks.

10. Do not allow any person to ride the forks, platform or load.

11. Park vehicle in a safe place when not in use.  Do not obstruct crossings, passageways or roadways.

12. When an industrial vehicle is left unattended, the load engaging means shall be lowered, controls neutralized, the power off and brakes set.  The operator may leave the engine running only if he is within 25 feet and can see the vehicle.  The other requirements still apply.

13. Stunt driving, racing and horseplay with vehicles will not be permitted.

14. Always wait until the vehicle is completely stopped and emergency parking brake is set before dismounting.

15. Sound horn at all blind corners, when passing other vehicles, pedestrians or workers, or whenever there is a stop sign indicating horn use.  Never use horn to startle people.

16. Obey all traffic signs.

17. When loading or unloading trucks and trailers, check that the truck brakes are set and properly place wheel chocks to prevent movement.

18. Report all incidents whether they involve personal injury, equipment, material damage, collision or material upsets to your supervisor immediately.

19. When floors are slippery with oil, grease, or water, clean up the area if possible, or reduce your speed and notify your supervisor immediately.

20. When lifting personnel on a fork truck an approved safety platform firmly secured to the lifting carriage must be used.

21. When ascending or descending grades the loaded fork shall be driven with the load upgrade.

22. Portable LP tanks may be stored only in racks provided for this purpose.  Do not store cylinders on the ground.

23. On forklifts with seat belts installed, it is mandatory for operators to properly wear the belt.

Fire Prevention and Flammable Liquids Safety Rules

1. Only use a fire extinguisher if you have been trained by your employer an based upon your level of confidence an training.

2. Fire extinguishers have a rating prominently displayed on them that identify what class of extinguisher they are. The rating follows:

Fire extinguishers can be of more than on  Class, with Class ABC being a common extinguisher available.  Class ABC extinguishers can be used on paper or wood, flammable liquids or electrical fires.

3. Become familiar with the location, operation and use of fir extinguishers in your area.

4. Fire fighting equipment and fire aisles must be kept clear and ready for use at all times.  Never block sprinkler heads with stored materials.

5.  Only approved solvents should be used for cleaning and degreasing.

6. Use as little solvent or flammable liquid as necessary to do the job.  Keep solvents in a labeled safety container and do not use around sparks or open flame.

7. Flammable liquid containers must be closed while not ins use.

8. Do not attempt any work involving a source of ignition near a pit, sewer, drain, manhole or enclosed space where flammable gases may be present.  Wait until the area has been declared safe for hot work (See your supervisor.)

* Class A - used for normal combustible materials such as paper or wood.

* Class B - used for flammable liquids.

* Class C - used for electrical fires.

* Class D - used for flammable metals, such as, sodium, magnesium and aluminum.

9.  Good housekeeping is our best protection against fires.  Do your part by disposing of all scrap, wiping, rags, paper, rubbish, etc. in proper containers.

10. Make sure all electrical equipment is in good condition.  Such things as worn or frayed extension cords, defective plugs and outlets, overloaded fuses and circuits are all fire hazards.

11. Obey “NO SMOKING” signs.  Discard tobacco products and matched in appropriate containers.  Observe the smoke free work environment policy and smoke only in designated areas.

12. Flammable liquids must be stored and used in appropriate containers.  (i.e. FM approved).

13. When flammable liquids are not being used, they should be stored in flammable liquid storage cabinets or designated areas.

14. Use appropriate bonding and grounding when transferring flammable liquids to another container.

Written Program Overview

A.        Confined Space Program

The confined space program addresses hazards within areas such as pits, machinery or other enclosed areas.  Confined spaces have been reviewed and are marked with confined space signs.  Unauthorized entry into confined spaces is strictly prohibited.

Definitions

ACCEPTABLE ENTRY CONDITION:  conditions that must exist in a permit space to allow entry and to ensure that employees involved with a permit-required confined space entry, can safely enter into and work within the space.

ACCEPTABLE ENVIRONMENTAL CONDITIONS: confined space workplace conditions in which uncontrolled hazardous atmosphere are not present, and which include any additional environmental criteria the employer may require for employee entry into a confined space.

ATTENDANT:  an employee stationed outside the confined space, trained as required by this Standard, assigned to monitor the employees inside this space and other spaces within the limits as authorized by the location.

AUTHORIZED ENTRANT: an employee who is authorized by the employer to enter a confined space.

BLANKING OR BLINDING:  the absolute closure or a pipe, line or duct, by fastening across its bore a solid plate or “cap” which completely covers the bore: which extends at least to the outer edge of the flange at which it is attached; and which is capable of withstanding the maximum upstream pressure.

CONFINED SPACE:  an enclosed space which:

a)     Is large enough an so configured that an employee can bodily enter and perform assigned work.

b)     Has limited or restricted means for entry or exit (examples are tanks, vessels, oils, pits and diked areas);

c)      Has one or more of the following characteristics:

·     contains or has known potential to contain a hazardous atmosphere;

·     contains a material with a potential for engulfment of an entrant;

·     has an internal configuration such that an entrant could be trapped or asphyxiated by inwardly converging walls, or a floor which slopes downward and tapers to a smaller cross section; of

·     contains any other recognized serious safety or health hazard.

DOUBLE BLACK AND BLEED:  the closure of a line, duct or pipe by locking and tagging a drain or vent which is open to the atmosphere in the line between two locked-closed valves.

EMERGENCY: any occurrence (including any failure of hazard control or monitoring equipment) event(s) internal or external to the confined space which could endanger entrants

ENGULFMENT: surrounding and effective capture of an employee by a liquid or finely divided solid substance.

ENTRANT:  an employee authorized to enter a confined space.  May serve as an attendant if this is approved by the permit.  May be fully trained employee to approve entry by others, and may enter the space covered by the permit provided by the attendant is informed.

ENTRY: the act by which a person intentionally passed through an opening into a confined space and includes ensuing work activities in that space.  The entrant is considered to have entered as soon as any part of the entrants face breaks th plane of an opening into the space.

ENTRY PERMIT: the written or printed document established by the employer, the content of which is based on the employers hazard identification and evaluation for that confined space (or class or family of confined spaces is a number of spaces may contain similar hazards) and is the instrument by which the employer authorizes his or her employees to enter that confines space.

ENTRY PERMIT SYSTEM:  the location’s written procedures for preparing and issuing permits for entry and returning the permit space to service.

HAZARDOUS ATMOSPHERE:  an atmosphere which exposes employees to a risk of death, incapacitation, injury or acute illness from one or more of the following causes.

a)     A flammable gas, vapor, or mist in excess of 10 percent of its lower explosive limit (LEL);

b)     An airborne combustible dust at a concentration that obscures vision at a distance of five feet (1.52 m) or less;

c)      An atmospheric oxygen concentration below 19.5 percent of above 22 percent.

d)     Any atmospheric condition recognized as immediately dangerous to like of health (IHLH).

HOT WORK PERMIT: the employer’s written authorization to perform operations which could provide a source of ignition such as riveting, welding, cutting, burning or heating.

IMMEDIATE DANGEROUS TO LIFE OF HEALTH (IDLH): any condition which poses an immediate threat of life; may result in irreversible or immediate, severe health effects; may result in eye damage; irritation or other conditions which could impair escape from the confined space.

INERTIN:  rendering the atmosphere of a confines space non-flammable, non-flammable, non-explosive or otherwise chemically non-reactive by such means as displacing or diluting the original atmosphere with steam or a gas that is non-reactive with respect to that space.

IN PLANT RESCUE TEAM:  a group of two or more employees designated and trained to perform rescues in confines spaces in their plant.

ISOLATION:  the separation of a permit space from unwanted forms of energy which could be a serious hazard to confined space entrants.  Usually accomplished by such means as blanking or blinding; removal of misalignment of pipe sections or spool pieces; double block and bleed; or lockout and tagout.

LINE BREAKING:  the intentional opening of a pipe, line or duct that is or has been carrying flammable, corrosive or toxic material, an inert gas, or any fluid at a pressure or temperature capable of causing injury.

LOW HAZARD CONFINED SPACE:  a confined space where there is an extreme low likelihood that an IDLH hazard could be present and where all other serious hazards have been controlled.

NON-PERMIT CONDITION:  any condition or set of conditions whose hazard potential exceed the Condition limits stated in the entry permit.

OXYGEN DEFICIENT ATMOSPHERE:  an atmosphere containing less than 19.5 percent oxygen by volume.

OXYGEN ENRICHED ATMOSPHERE:   an atmosphere containing more than 22  percent oxygen by volume.

PERMIT REQUIRED CONFINED SPACE:  a confined space that has one or more of the following characteristics:

a) contains or has potential to contain a hazardous atmosphere

b) contains a material that has the potential for engulfing an entrant

c) has an internal configuration such that an entrant could be trapped or asphyxiated by inwardly covering walls or by a floor which slopes downward and tapers to a small cross-section; or

d) contains any other recognized serious safety or health hazard.

RETRIEVAL LINE:  a line of rope secured at one end to the worker by a chest-wait or full-body harness, with the other end secured to either a lifting (or other retrieval) device or to any anchor point located outside the entry portal.

ATMOSPHERIC CHECKS:

·     Combustible gas, vapor levels must be below 10% of the Lower Explosive Limit (LEL).

·     The oxygen content must be between 19.5 % and 22% (% by volume of air).

·     The carbon monoxide (CO) level must be below 35 ppm for unrestricted work.  At levels between 35-100 ppm, an employee may work under the following restrictions:

            1. Only 15 minutes exposure per hour is permitted AND

            2. Continuous air monitoring is required. At levels greater than 100 ppm, a supplied air respirator (airline or SCBA) must be used.  Respirator users must be trained an qualified on the device to be used.  This requirement applies no matter how short the duration of the task.

B.        Hazard Communication

The hazard communication program ensures that employees have the information necessary to understand the hazards of a material, protect themselves from the hazards, and use the material in a safe manner.  Material Safety Data Sheets (MSDS) and container labels can be used to determine the hazards of the materials that you use.  There are several locations in the plant where MSDS are maintained.  See your supervisor for the closets MSDS.

No material may be brought upon ARCOR® International without prior approval by the ARCOR® EHS Department.

C.        Lockout/Tagout Program

This program details the tagout/lockout program for working with equipment that has energy sources such as hydraulic, pneumatic or electric which could accidentally be released and injure an employee working onto equipment or employees in the area.

The following is ARCOR®’s program for lockout/tagout.  Contract employees must understand and comply with this program or use a similar program which must be reviewed and approved by your ARCOR® Representative.

General Instructions

In order to maintain strict control of tagout/lockout procedures, only employees that have been trained and who are qualified to lockout/tagout will be authorized to shut down or restore equipment or process to operation and perform tagout/lockout procedures.

Lockout.  Under the new OSHA standard, the use of a padlock is the preferred method of locking out equipment before service work is performed.  In most cases, equipment can be locked out by physically installing a lock on electrical switch gear, valves, levers. etc, to prevent movement until it is returned to service.  In order to comply with this standard, the following provisions for equipment lockouts will apply:

1.  All authorized employees will be issued a long-shank padlock that is individually keyed for their own use.

2.  Each padlock will be tagged with the authorized employee’s name and operating department.

3.  Each lock will have two keys, one for the authorized employee to whom the lock is issued and one for his/her department supervisor (unless a submaster key system is used).

4.  The department supervisor will be responsible for control of spare keys and for maintaining a list of the locks issued, including extra locks.

5.  In the event a key becomes lost, the supervisor will be responsible for having the lock re-keyed or replaced.

6.  The department supervisor will control use of the spare or master keys in the event that one of his/her authorized employees is unavailable to remove the lock.  Under such circumstances, the supervisor will verify that the person is not at the facility, and make a reasonable attempt to contact him/her to inform him/her of the removal.  If efforts to contact the employee are unsuccessful, then a company padlock, controlled by the supervisor can be sued until the employee is notified so repair work can be resumed.

7.  If the employee(s) whose tagout/lockout has been removed cannot be reached, the supervisor will be required to notify he employee by telephone or written notice before the employee(s) return to work.  In such instances the form entitled “Notice of Tagout/Lockout Removal” will be used as documentation.

8.  Whenever a lockout is performed a red “DO NOT OPERATE” tag must be placed through the shank of the padlock.

9.  Annual reviews of tagout/lockout procedures will be documented by plant and corporate safety personnel to ensure that correct procedures are being followed.

10.  Under revised OSHA standards, new or modified equipment purchased or renovated after October 31, 1989, must be adapted with lockable, isolated devices.  It will be the responsibility of the Purchasing, Maintenance and Engineering departments to purchase, install or design such devices on new or modified equipment in the future.

Lockout.  Under some circumstances the use of a padlock to isolate electrical or mechanical energy may not be practical or feasible.  In such cases, a tagout or equipment using a “DO NOT OPERATE” tag can be used.  However, it must be clearly understood that lockout will be given first consideration.  The following provisions will be used when equipment is tagged out for servicing:

* Only authorized personnel as outlined in “General Instructions” above will be permitted to fill out an place a tag out.

* All tagouts must contain the name of the person.

* The tags must be attached to the energy source shut off mechanisms with a self-locking plastic or nylon tie wrap capable of withstanding at least 50 pounds of force.

Warning Tags:

* A yellow WARNING tag will be used to prevent operation of equipment which could result in damage or create a potential hazard.

* WARNING tags can be issued by any supervisor, manager, Safety or Engineering personnel.  these tags will be used to remove from service until repairs or  installation work can be completed.

* The red DO NOT OPERATE tag is designed to protect people, the yellow WARNING tag is designed to protect equipment.

Warning Tagout Procedure (yellow tag):

* When a piece of equipment is found in need of service or repair that is beyond the scope and responsibility of the equipment operator, it will be his responsibility to contact his/her supervisor and report it.

* The supervisor will stop operations if necessary, complete a yellow tag and place on the machine controls and contact the Maintenance Department.

*  When repairs have been completed, the individual who placed th yellow tag or a designated alternate will be contacted to approve the work and remove the tag for release to operation.

* WARNING tags can also be used to remove obsolete or unsafe equipment form service, pending its disposal or scrapping.

Tagout/Lockout of equipment does not include routine servicing or adjustments that are done under normal production operations; however, if guards or safety devices are removed or bypassed, or if employees are required to place any part of their body in a point of operation or they are exposed to other hazards that could result in injury, then tag/out lockout procedures must be followed.

Tagout/Lockout Procedure.  Mechanically powered equipment of process.  Examples of this type of equipment include, but are not limited to,,those that are powered by internal combustion engines, air, hydraulics, gas, steam, gravity or spring tension.

* Review the proposed work with the supervisor in charge of he equipment to determine what service is needed an coordinate shut-down of the equipment process.

 *Use normal stop procedures to shut down equipment and place it in the “off” or “safe” position.

 *Tagout/Lockout the isolating devices in the “safe” or ‘off” position and try the lockout to make certain it cannot be moved.

* Test the machine start controls to make sure the isolating devices have provided a complete shutdown and that nothing can be moved.  Use chocking where necessary.

* Test and inspect for stored air, gas, steam, hydraulics, etc.  That may remain in piping, cylinders, etc as necessary.

* Also note that closed valves may leak an that capping, disconnection may be needed.

* Tagout bleed valves in the open position and tagout disconnected piping at both ends.

* Review equipment blue prints and related technical information as needed to insure all energy sources have been identified and brought to a zero energy state.

Tagout/Lockout of Electrically Powered Equipment.  Examples of this equipment include, but are not limited to welders, AC/DC motors and drives, transformers, lighting systems, generators, power distribution systems, heating elements, battery powered equipment, charges, etc.

Electrical disconnect devices are required to be clearly labeled and kept up-to-date and be available for use by authorized personnel to conduct installation or repairs.  Only qualified personnel are permitted to conduct electrical work.

* Review the proposed work with the supervisor in charge of he equipment to determine what service s needed and coordinate shut-down of the equipment or processes.

* Use normal stop procedures to shut down equipment and do not disconnect main switches or circuit breakers while the equipment is under a load.  Safe procedures to prevent electrical hazards will be determined before any circuit is energized or deenergized to prevent arching, fire or explosions.

* Lockout and tagout the isolating disconnect switches and/or circuit breakers in the “off” position and try the lockout to make certain in cannot be moved.

* Test the machine start control to make sure the isolating devices have provided a complete shut-down.  use chocking as necessary.

* Test and inspect for stored energy as discussed above in “Mechanically-powered Equipment or Process”.

*  When electrical work is involved, the blades of he disconnect switch must be verified visually that they are opened and a meter to check phase-to phase and phase-to ground readings must be made to insure all electrical energy has been disconnected or discharged.  Particular attention must be given to in-line capacitors or backfeed voltages.  Therefore, any electrical associated exposed contact surfaces that may be touched will be tested.

* The use of push buttons, toggle switches, pressure switches, limit switches or similar control circuit devices for tagout/lockout protection is not permitted.

* Pulling fuses cannot be substituted for tagout/lockout.  One switch may feed several motors individually fused.  In such cases, disconnect, tape or tagout the wires from the load side of the fuse clips.

* At any time a tagout is used without a lock for electrical work, at least one additional safety measure as a fail-safe must be used (i.e. opening of an extra disconnect device, blocking of another control switch, or removal of an isolating circuit).

* In instances where plug/cord equipment is being serviced, a red “DO NOT OPERATE” tag will be filled out an attached to the plug end of the cord.

Restoration of Equipment to Service.  When equipment repair or servicing has been completed the following procedures will be implemented to restore equipment service.

* The authorized person(s) who performed the servicing and placed the tagout/lockout will verify that all repairs have been completed and that all equipment safeguards have been replaced and will then notify those who placed the yellow WARNING tag that the equipment is ready.

* The person who placed the WARNING tag (or the alternate) will go to the site , inspect the work and coordinate the start-up of the equipment.

* Before the tagout/lockout is removed, the person who conducted the service work will inspect the equipment to ensure that all tools, blocking, or other equipment or components are operational.

* All affected people will be notified of the start-up and removal of he tagout/lockout, an the area will be inspected to make certain all people have been cleared out of the area to a safe location.

* Each lockout an/or tagout device will be removed by the individual who placed it.

* The person who placed the yellow tag will then approved the repairs, remove the tag, sign it off, and give it to the service person to document that the equipment has been released.

* In some situations, it may be necessary for maintenance personnel to start up equipment for testing before it is ready to be released.  This may require the temporary removal of tagout/lockout devices.  The same cautions stated above must be followed.  When testing has been completed, tagout/lockout procedures must again be applied t bring equipment back to a zero state of energy.

Tagout/Lockout Procedures for Shift Changes

* When an authorized service person cannot complete a job by the end of the work shift, it my be necessary to turn over the job to another coworker on the following shift.  When an authorized person leaves at the end of his/her shift, his/her individual tagout/lockout must be removed and replaced with the following shift workers tagout/lockout.

* In the event that no one is available to take over the job during the shift change, the maintenance supervisors must be contacted to make arrangements for service continuation.  The maintenance supervisor can use a “company” tag and lock that are under his personal control until the job is assigned to another person.

* In the event that a worker leaves without removing a personal tag/lockout, refer to “Lockout” #6 and #7 on pages 20 & 21.

Multiple Tagout/Lockout.  In some situations a number of service personnel may be involved in a repair or installation job that requires a multiple tagout/lockout, especially for jobs involving multiple departments or outside contractors.  In such instances, a scissors clasp or multiple locking hasp will be used to ensure the safety of each individual that is working on the equipment.

Group Tagout/Lockout

* Under some circumstances, where multiple work groups are working on a common job, it will be necessary to conduct a group tagout/lockout.

* There are currently four (4) types of group tagout/lockout methods that are suggested under OSHA regulations.

* Each of these tags usually involve th use of lock boxes which control the keys to multiple locations and crews or the assignment of one responsible person to control the tagout/lockout of particular groups.

* In cases of group tagout/lockout procedures, the four tags permitted by OSHA, which are outlined in the addendum to this practice should be referred to.

Contractors Tagout/Lockout Procedures

* Whenever it is necessary for a contractor to conduct repairs or do installation work on company premises, the project must be reviewed first with an ARCOR® representative from the Engineering or the Maintenance Department to determine the need to institute a tagout/lockout or equipment or process, especially in those instances where multiple work crews or ARCOR® personnel are involved.

* Contractors who have a tagout/lockout procedure will be responsible for using their own locks and tags and must demonstrate that their procedures comply with OSHA Standard 1910.147.

* Contractors’ tagout/lockout procedures and tags will be reviewed and communicated to any affected ARCOR® employee before work begins.

* In those instances where ARCOR® personnel are working along with contractors, each will arrange for a separate tagout/lockout for their respective employees’ safety.

* Contractors who do not have a tagout/lockout procedure will still be require to follow OSHA Standards.  In such instances, the respective ARCOR® maintenance manager of supervisor can review our procedures with them and arrange for a temporary loan of padlocks and tags, which will be under the direct control of the contractor until they can provide their own.

* Contractors who do not have a tagout/lockout procedure will be encouraged to provide their own tags, locks and procedures in order to be eligible to bid on future company contracts.

* The Purchasing Department will notify contractors in writing of their need to comply with tagout/lockout provisions to maintain bidding eligibility.

Tagout/Lockout Training

* In order to comply with OSHA Standard, an in-house training program to review and communicate ARCOR® procedures and OSHA requirements will be conducted for authorized personnel and those who may be affected.  Refresher training will be conducted annually.

Enforcement

* It will be the responsibility of each plant and division manager through their respective supervisors and staff to enforce the use of tagout/lockout procedures.

* Failure to use tagout/lockout procedures when required will result in disciplinary action.  Any employee who attempts to remove, alter, bypass or in any way override a tagout/lockout without authorization may be terminated.  Contractors who fail to observe tagout/lockout procedures may be removed from the work site and restricted from future bidding on company contracts.

Addendum to Group Tagout/Lockout Procedures from OSHA Instruction STD 1-7.3

Type A:  Each authorized employee places his/her personal lock or tag upon each energy isolating device and removes it upon departure from that assignment.  Each authorized employee verifies or observes the de-engergizing of the equipment.

Type B:  Under a lockbox procedure, a lock or job-tag with tab is placed upon each energy isolation device after de-energizing.  The key(s) and remove tab(s) are then placed into a lockbox.  Each authorized employee assigned to he job then affixed his/her personal lock or tag to the lockbox. 

As a member of a group, each assigned employee verifies that all hazardous energy has been removed or the energy isolating device turned on until the appropriate key or tab is matched to its lock or tag.

Type C:  After each energy isolating device is locked/tagged out and the keys/tabs placed into a master lockbox, each servicing/maintenance group “principal” authorized employee places his/her personal lock or tag into a satellite lockbox to which each authorized employee in that specific group affixes his/her personal lock or tag.  As a member of a group, each assigned authorized employee verifies that all hazardous energy has