Risk ManagementGeneral Industry

RISK MANAGEMENT MANUAL

FOR

GENERAL INDUSTRY

Brown & Brown of Lehigh Valley, Inc. 268 Brodhead Road

Bethlehem, PA 18017 800-634-8237

www.bbinslv.com 2005

Brown & Brown of Lehigh Valley, Inc. 2005

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TABLE OF CONTENTS INTRODUCTION

Purpose 7 Authority 7 Scope 8 Review and Evaluation 8

CHAPTER 1 - GENERAL PRINCIPLES AND GUIDELINES

I. Introduction 9 II. Safety First Policy 9 III. Individual Cooperation Necessary 9 IV. Safety Program Goals 9 V. Company Safety Policy 10 VI. General Safety Rules for Employees 10 VII. Responsibilities of Safety Officer/Safety Committee 11 VIII. Safety Equipment 12 IX. Agreement to Participate 12

CHAPTER 2 - GENERAL CODE OF SAFE WORK PRACTICES

I. General Fire Safety 13 II. Power Tools 13 III. Machine Guarding 14 IV. Confined Spaces 15 V. Industrial Trucks/Forklifts 15 VI. Noise 16 VII. Fueling 17 VIII. Piping Systems 17 IX. Compressors and Compressed Air 17 X. Hoist and Auxiliary Equipment 17 XI. Ventilation 18 XII. Ergonomics 18 XIII. Safety Posters 18 XIV. Licenses and Permits 19 XV. Walkways 19 XVI. Floor and Wall Openings 19 XVII. Tool Maintenance 20 XVIII. Ladders 20 XIX. Combustible Materials 20 XX. First Aid Kits 21 XXI. Environmental Controls 21


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CHAPTER 3 - CHEMICAL SAFETY

I. Introduction 23 II. Hazcom Plan 23 III. Hazardous Chemical Exposures 26 IV. Task Evaluation 27 V. General Responsibilities 27 VI. Labels 28 VII. Chemical Storage 28 VIII. Emergencies 28 IX. Disposal of Chemicals 28

CHAPTER 4 - ELECTRICAL SAFETY

I. Introduction 31 II. Responsibilities 31 III. General Procedures 32 IV. Working with Energized Equipment 33 V. General Safety Rules 34 VI. Lockout/Tagout Procedures 36 VII. Elevated Locations 36 VIII. Safe Practices 36

CHAPTER 5 - FIRE SAFETY

I. Introduction 38 II. Basic Procedures 38 III. Fire Drills/Evacuations 38 IV. Fire Extinguishers 39 V. Supervisors 39 VI. Fire Fighting Equipment 39 VII. Fire Exits 39 VIII. Fire/Emergencies 40

CHAPTER 6 - GASES

I. Introduction 41 II. General Procedures 41 III. Oxygen 43 IV. Chlorine Gas 43 V. Acetylene 43 VI. Inspection of Cylinders 44 VII. Cylinder Handling 44 VIII. Cylinder Storage 44


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CHAPTER 7 - MATERIALS HANDLING

I. Introduction 46 II. Manual Lifting 46 III. Mechanical Lifting 47 IV. Powered Industrial Trucks 47 V. Changing and Charging Batteries/Propane Cylinders 47 VI. Truck Operations 48 VII. Traveling 48 VIII. Maintenance of Industrial Trucks 48 IX. Overhead Cranes 49 X. Training 49 XI. Sling Safety 51

CHAPTER 8 - PERSONAL PROTECTIVE EQUIPMENT

I. Introduction 52 II. Training 52 III. Eye and Face Protection 52 IV. Respirator Protection 53 V. Head Protection 53 VI. Foot Protection 54 VII. Electrical Protective Devices 54 VIII. Hand Protection 54 IX. Hearing Protection 54 X. Fall Protection 54

CHAPTER 9 - DRIVER AND VEHICLE SAFETY

I. Introduction 55 II. General Vehicle Operating Procedures 55 III. License Requirements 55 IV. Accident Reporting 56 V. Maintenance 56 VI. Training 57 VII. Cell Phone Usage 57

CHAPTER 10 - MACHINERY AND MACHINE GUARDING

I. General Requirements 58 II. Woodworking Machinery 58 III. Abrasive Wheel Machinery 58 IV. Mechanical Power Presses 59 V. Mechanical Power Transmission Apparatus 60


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CHAPTER 11 - JOB HAZARD ANALYSIS

I. Introduction 61 II. Job Analysis 61 III. Steps for a Job Hazard Analysis 61

CHAPTER 12 - SAFETY TRAINING 63 CHAPTER 13 - DISASTER PLANNING

I. Introduction 64 II. Emergency Numbers 64 III. Plan Description 64 IV. Employee Emergency Numbers 64 V. Media Relations 64 VI. Insurance Information 64 VII. Local Repair and Maintenance Contacts 64 VIII. Computer System Back up/Repair Information 64 IX. Alternate Site Plan 65 X. Management Responsibilities 65 XI. Employee Responsibilities 65 XII. Vendors 65 XIII. Reporting a Catastrophe 65 XIV. Bomb Threat 65 XV. Fire 66 XVI. Gas Leak 66

CHAPTER 14 BLOODBORNE PATHOGENS

I. Policy 68 II. Program Administration 68 III. Method of Implementation and Control 68 IV. Post Exposure Evaluation & Follow up 70 V. Procedures for evaluation 71 VI. Recordkeeping 71 VII. Vaccine Declination 71

APPENDIX A Accident Investigation Form 73 B Employee Safety Suggestion Communication Program 75 C Company Safety Policy 76 D Agreement to Participate 77 E Hearing and Site Conservation Program 78 F Fire Drill Documentation 79 G Fire Safety Inspection Checklist 80 H PPE Certification 81 I Respiratory Selection for Routine Use of Respirators 82 J Accident Date Checklist 83


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K Preventive Maintenance Checklist 84 L Mechanical Power Press Record of Inspection 85 M Job Hazard Analysis Form 86 N Training Sign in Sheet 87 O Mold Awareness 88


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RISK MANAGEMENT SAFETY MANUAL

INTRODUCTION I. PURPOSE The purpose of risk management is to assure that the Company delivers services and products in an environment and in a manner conducive to the safety of all employees, customers and visitors. The program seeks to:

1) Reduce the possibility of personal injury from accidents, natural disasters or negligence. 2) Reduce the possibility and severity of property losses due to fire, theft or natural disasters. 3) Protect the financial resources and reputation of the Company from liability and adverse

publicity. II. AUTHORITY AND ORGANIZATION The President/Owner and/or Financial Officer are responsible for the oversight of all risk management and health and safety programs of the Company. He or she approves the appointment of the Risk Manager/Safety Officer and Safety Committee Members, and assures the financial and legal resources for the implementation of risk management and health and safety programs. The Risk Manager/Safety Officer is responsible for the development, implementation and maintenance of the Companys risk management program. The purpose of the Health and Safety Committee is to ensure that the companys physical structure, emergency equipment, contractors or manufacturing equipment, vehicles, utilities, and mechanical equipment are properly maintained and promote the safety of all employees, customers and visitors. Representatives of the Health and Safety Committee will inspect the facility and operations of the Company on a prescheduled basis to identify activities or procedures which may lead to adverse incidents. The Health and Safety Committee may review previous incidents to establish existing trends as well as individual occurrences to determine the severity and requirement for immediate corrective action. The Health and Safety Committee will meet monthly and will include representative of employees and management from each department within the Company. All employees will participate in the Companys risk management program by following the Companys policies and procedures; by identifying and reporting safety concerns and environmental hazards, and by affirming, as part of their duties, the accurate and timely reporting of all incidents and near misses.


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III. SCOPE Risk management means the identification, investigation, analysis, and evaluation of potential risks and safety hazards and the determination of the most effective means of reducing or eliminating identifiable risks. Risk management encompasses all services of the Company, and is defined more specifically to include:

1. Establishment and implementation of procedures for reporting incidents internally and to state agencies as required; maintenance of a database of incidents, analyzing trends, and presenting annual reports to upper management. (APPENDIX A-Accident Investigation Form)

2. Conducting and reviewing safety inspections to identify safety risks and environmental

hazards.

3. Establish and implementation of emergency and disaster plans.

4. Maintaining an interdisciplinary Health and Safety Committee which reviews health and safety concerns identified through incident reports and physical inspections; recommending remedial action to the President/Owner and Financial Officer, and annually evaluating the risk management program.

5. Compliance with Health and Safety Programs and current statutes and regulations.

6. Planning and coordinating orientation and ongoing training (e.g. incident reporting,

emergency preparedness, fire safety, vehicle safety, etc.) the maintenance of current safety publications and MSDS documentation.

IV. REVIEW AND EVALUATION The risk management program will be evaluated annually by the Health and Safety Committee to determine its effectiveness in the reduction of adverse incidents. The Health and Safety Committee will also review the emergency and disaster plans and update them as necessary.


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CHAPTER 1

GENERAL PRINCIPLES AND GUIDELINES I. INTRODUCTION Every Employer should have a written Risk Management plan. This is our plan. Please read it carefully. While no plan can guarantee an accident free workplace, following the safety procedures set forth in this manual will significantly reduce the risk of danger to you and your co-workers. State and Federal Law, as well as Company policy, make the safety and health of our employees the first consideration in operating our business. Safety and health in our business must be part of every operation, and every employees responsibility at all levels. It is the intent of our Company to comply with all laws concerning the operation of the business and the health and safety of our employees and the public. To do this, we must be aware of the conditions in all work areas that can produce or lead to injuries. No employee is required to work at a job known to be unsafe or dangerous to his or her health. Your cooperation in detecting hazards, reporting dangerous conditions and controlling workplace hazards is a condition of employment. Inform your supervisor immediately of any situation beyond your ability or authority to correct. Employees will not be disciplined or suffer retaliation for reporting a safety violation in good faith. (APPENDIX B Employee Safety Suggestions Communication Program) II. SAFETY FIRST PRIORITY The personal safety and health of each employee is of primary importance. Prevention of injuries and illnesses is of such importance that it will be given precedence over operating productivity. To the greatest degree possible, management will provide all mechanical and physical protection required for safety and health, but our employees must bear primary responsibility for working safety. A little common sense and caution can prevent most accidents from occurring. III. INDIVIDUAL COOPERATION NECESSARY We maintain a safety and health program conforming to the best practices of our field. To be successful, such a program must embody proper attitudes toward injury and illness prevention on the part of all supervisors and employees. It requires cooperation in all safety and safety health matters, not only by the employer and employees, but also between each employee and his or her co-workers. Only through such a cooperative effort can a safety program in the best interest of all be established and preserved. Safety is no accident; think safety and the job will be safer. IV. SAFETY PROGRAM GOALS The objective of the Company is a safety program that will minimize the number of injuries and illnesses, not merely in keeping with, but surpassing the best experience of similar operations by others. Our goal is zero accidents and injuries.


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V. COMPANY SAFETY POLICY (APPENDIX C Company Safety Policy) VI. GENERAL SAFETY RULES FOR EMPLOYEES It is the policy of our company that everything will be done to protect you from accidents, injuries, and/or occupational disease while on the job. Safety is a cooperative undertaking requiring an ever-present safety consciousness on the part of every employee. If an employee is injured, positive action must be taken promptly to see that the employee receives adequate treatment. All operations must be planned to prevent accidents. To carry out this policy, the following rules will apply:

1) All employees shall follow the safe practices and rules contained in this manual and such other rules and practices communicated on the job or as recommended by any manufacturer guidelines. All employees shall report all unsafe conditions or practices to their immediate supervisor.

2) Observe all smoking, safety and fire prevention regulations and signs.

3) Good Housekeeping must be practiced at all times in the work area. Clean up all waste and eliminate any dangers in the work area. Work sites must be kept clean and orderly. Spills must be cleaned up immediately

4) Suitable clothing and footwear must be worn at all times. Personal Protective Equipment (hardhats, respirators and eye protection) will be worn as required for each job.

5) All employees will participate in a safety training conducted by the Safety Committee once every year or as your position deems necessary.

6) There will be no consumption of liquor or beer on the job. Anyone under the influence of intoxicating liquor or drugs, including prescription drugs, which might impair motor skills and/or judgment, shall not be allowed on the job.

7) Horseplay, scuffling, and other acts which tend to have an adverse influence on the safety or the well being of other employees is prohibited.

8) Work shall be well planned and supervised to avoid injuries in the handling of heavy

materials and while using equipment. 9) Employees shall not be permitted to work if their ability or alertness is so impaired by

fatigue, illness, or other causes that personal injury to the employee or others might occur. 10) Employees should be alert to see that all guards and other protective devices are adjusted and

used properly. Employees shall report deficiencies promptly to their immediate supervisor.

11) Employees shall not handle or tamper with any electrical equipment, machinery, or air or water lines outside the scope of their duties.


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12) All injuries should be reported to supervisors promptly so that arrangements can be made for

medical or first aid treatment. 13) When lifting heavy objects, use proper lifting techniques and the equipment that is indicated

by policy or training. 14) Employees with long hair, regardless of sex, must maintain their hair in such a way that it

does not become a safety hazard. 15) Lock out/Tag out tags shall not be removed unless authorization is given.

16) Drivers and equipment operators must make daily safety inspections of their vehicles or

machines prior to the start of their shift. Defects are to be reported immediately to your immediate supervisor.

17) No jewelry is to be worn while operating machinery or equipment. 18) Keep any doors or means of egress clear. Do not pile or stack any boxes in the aisles or in

front of any door. 19) All combustibles must be stored safely and removed promptly. Combustible dust must be

cleaned up to prevent the dust from going into suspension. VII. RESPONSIBILITY OF SAFETY OFFICER/SAFETY COMMITTEE The person or persons who are responsible for the safety program shall have Company authority to implement the program and:

1) Develop and implement rules of safe practices for each function within the Company.

2) Develop and implement safe operating rules for uses of electrical and mechanical equipment consistent with manufacturers recommendations and specifications.

3) Develop and implement a system to encourage employees to report unsafe conditions immediately.

4) Conduct a thorough investigation of each accident, whether or not it results in an injury, to determine the cause of the accident, and to prevent a recurrence.

5) Train supervisors in safety responsibilities.

6) Develop and implement an employee safety education program.

7) Conduct monthly/quarterly safety inspections.


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8) Monitor scheduled and unscheduled inspections to identify and correct unsafe working conditions. Special attention shall be given to serious concealed dangers.

9) Maintain records of training, injuries, periodic inspections, corrective actions and investigations.

VIII. SAFETY EQUIPMENT Personal Protective Equipment is furnished by the Company. It is the employees responsibility to notify your immediate supervisor if there is a problem with your PPE. Wear your equipment properly all snaps and straps are to be fastened and individual fit must be maintained. Your supervisor will advise you as to what protective equipment is required for your job and in your area. IX. AGREEMENT TO PARTICIPATE Every employer is required to provide a safe and healthful workplace. Our Company is committed to fulfilling this requirement. A safe and healthful workplace is one of the highest priorities of the Company. The information in this manual constitutes a written injury and illness prevention program. While we cannot anticipate every workplace hazard, the following principals should guide your conduct. To be safe, you must never stop being safety conscious. Study the guidelines contained in this manual. Discuss the workplace situation with your supervisor. Attend all company sponsored training and safety meetings. Read all posters and warnings. Listen to instructions carefully. Follow the Code of Safe Work Place Practices contained herein. Participate in accident investigations as required. Accept responsibility for the safety of others. Maintain all required documentation. By signing the acknowledgement at the end of this handbook, each employee promises to read and implement this injury and illness prevention program. If you dont understand any policy, please ask your supervisor. (APPENDIX D-Agreement to Participate)


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CHAPTER 2 GENERAL CODE OF SAFE WORK PRACTICES

I. GENERAL FIRE SAFETY All fire doors and fire exits must be maintained in good operating condition. Fire doors should be unobstructed and protected against obstructions. Fire door fusible links must be in place. All automatic sprinkler water control valves, if any, air and water pressures should be checked routinely. The maintenance and standards of the sprinkler system is the responsibility of the Safety Officer, per OSHA Standard 1910.159. Proper guards should protect sprinkler head to avoid any possible exposure damage. Proper clearance of at least 18 inches must be maintained below sprinkler head. Where sprinkler heads are permanently installed, nozzle heads should be arranged so that water will not be sprayed onto operating electrical switch boards and equipment. Nozzle heads should be checked periodically to be certain that they are not bent or twisted from their original position. Portable fire extinguishers are provided in adequate number and are located throughout the facility. Fire extinguishers are mounted in readily accessible locations. The extinguishers are recharged regularly and the date of last inspection is noted on their tags. All extinguishers must be serviced, maintained and tagged at intervals not to exceed one year. All employees are annually instructed in the use of extinguishers and fire protection procedures. Notify your immediate supervisor of any damage to an extinguisher. Fire extinguishers are selected for the types of material and placed in areas where they are to be used. These fire extinguishers are classified as follows:

Class A Ordinary combustible materials fires Class B Flammable liquid, gas or grease fires Class C - Energized electrical equipment fires

Appropriate fire extinguishers must be mounted within 75 feet of outside areas containing flammable liquids and within 10 feet of any inside storage area for such materials. In most cases of a real emergency, call 911. State your name, the nature of the emergency and exact location of injury. Answer all questions completely. DO NOT use 911 for routine calls to police or fire departments. II. POWER TOOLS Any employee using a power tool must be properly trained on the specific tool. Each power tool should be stored unloaded and in a locked container when not being used. Prior to each use the tool must be inspected for obstructions or defects. When using a power tool any necessary Personal Protective Equipment must be worn while operating the tool. These rules apply to all power tools, but especially important when handling portable saws, drills and power screw drivers.

1) Check your equipment before you use it.


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2) All grinders, saws and similar equipment should be equipped with appropriate safety guards. Power tools should not be used without the correct shield, guard, or attachment, which is recommended by the manufacturer.

3) Portable circular saws must be equipped with guards above and below the base shoe.

Circular saw guards should be check periodically and before each use to assure they are not wedged up, thus leaving the lower portion of the blade unguarded.

4) All rotating or moving parts of equipment should be guarded to prevent physical contact. 5) All cord connected, electrical operated tools and equipment should be effectively grounded. 6) Effective guards must be in place over belts, pulleys, chains, sprockets, on equipment such as

concrete mixers, air compressors, etc. 7) If portable fans are provided, they must be equipped with full guards or screens having

openings one half inch or less. 8) Power tools are either battery operated or wired. If battery operated, do not under estimate

their power. Remember that a battery pack contains toxic chemicals and emits a low voltage electric current. Never drop or incinerate the battery pack or a tool with a self contained power source.

9) Hard wired equipment can be portable or fixed. Typically used with extension cords, the

more powerful hard wired equipment presents a double safety problem: the actual equipment plus its electrical power source.

10) Pneumatic and hydraulic hoses on power rated tools should be checked regularly for

deterioration or damage. III. MACHINE GUARDING Before operating any machine, each employee must have completed a training program on safe methods of machine operation. There will be monthly inspections of machinery and equipment, the result of which will be documented. All machinery and equipment must be kept clean and properly maintained. There must be sufficient clearance provided around and between machines to allow for safe operations, set up, servicing, material handling and waste removal. All equipment and machinery should be securely placed and anchored when necessary, to prevent tipping or other movement that could result in personal injury. When warranted machinery should be bolted to the floor and the electrical cord to the machinery fixed with a breaker or other shut off device to stop power in case of machine movement. All power shut off switches must be within reach of the operators position at each machine. Electrical power to each machine shall be capable of being locked out for maintenance, repair or security. The metal parts of electrical machines must be bonded and grounded.


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The machine guarding must be secure and arranged so they do not present a hazard. At no time, except for maintenance and repair, should the guarding be removed from the machine. Your immediate supervisor will be responsible to see that the employee has the proper training and that safe working practices are being used. IV. CONFINED SPACES Before entry into a confined space, all impellers, agitators, or other moving equipment contained in the confined space must be locked out. Ventilation must be either natural or mechanically provided into the confined space. All hazardous or corrosive substances that contain inert, toxic, flammable or corrosive materials must be valved off, blanked, or disconnected. Atmospheric tests should be performed to check for oxygen content, toxicity and explosive concentration. Atmospheric tests must be performed on a regular basis in a confined area where entry is required. The area must also be checked for decaying vegetation or animal matter that could produce methane. Adequate lighting must be provided within the space. If the confined area is located below the ground or near where motor vehicles are operating, care must be taken that vehicle exhaust or carbon monoxide does not enter the space. When personnel enter a confined area, assigned safety standby employees must be in the area and must be alert to the work being done. They should be able to sound an alarm if necessary and to render assistance. Those standby employees must be trained to assist in handling lifelines, respiratory equipment, cardiopulmonary resuscitation (CPR), and first aid and be able to employ rescue equipment that will remove the individual from the confined space. Standby personnel should be in teams of tow during such an operation and within the vicinity if working separately. There must also be an effective communication system utilized while operation is occurring. When equipment which uses oxygen, such as salamanders, torches or furnaces, is used in a confined space, adequate ventilation must be provided to guarantee oxygen contents and combustion for the equipment. When this equipment is used, adequate measures must be taken to assure that exhaust gases are vented outside the enclosure. When gas welding or burning is used, hoses must be checked for leaks. Compressed bottled gas must be outside the area, and torches must be lit outside the area as well. The atmosphere must be tested each time before lighting a torch. V. INDUSTRIAL TRUCKS/FORKLIFTS Only trained personnel are allowed to operate any motorized vehicle or industrial truck. Lift truck operating rules must be posted and strictly enforced. Any and all safety equipment provided with any lift truck or industrial truck will be used at all times. Directional lighting is also provided on each truck that operates in an area with less than two foot candles per square foot of general lighting. Each industrial truck must have a warning horn, whistle, gong or other device which can be clearly heard above the normal noise in the area where operated. Before using a forklift, check that the brakes on each are capable of bringing the vehicle to a complete and safe stop when fully loaded. The parking brake must effectively prevent the vehicle from moving when unattended.


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Each truck must bear a label or some identifying mark indicating approval by the testing laboratory. Only approved trucks may be used in designated areas. Any battery charging or refueling will only be done in designated areas, with brakes applied at all times. Refresher training will be done when:

1) The operator has been involved in an accident or near miss. 2) The operator has been observed operating in an unsafe manner. 3) The operator has received an evaluation that reveals that he or she is not operating the truck

safely. 4) The operator is assigned to a different type of truck. 5) A condition in the workplace changes in a manner that could affect safe operation of the

truck. 6) At least every three years.

At no time shall the forklift or industrial truck carry a passenger. When left unattended (operator is 25 feet or more away from the vehicle, or whenever the vehicle is not in view of the driver) load engaging means shall be fully lowered, controls shall be neutralized, power shall be shut off and brakes set. Wheels shall be blocked if the truck is parked on an incline. When motorized hand and hand/rider trucks are operated, and when the operator releases the steering mechanism, make certain that both brakes are applied and power to the motor is shut off. Maintenance records are available so that a driver can check on the servicing of the truck in case of questions. VI. NOISE Noise levels are measured using a sound level meter or an octave bank analyzer, and records of noise level measurements are kept. Engineering controls will be used to reduce excessive noise levels. When engineering controls are not feasible, administrative controls (i.e. worker rotation) will be used to minimize individual employee exposure to noise. An ongoing prevention health program will be utilized to educate employees on safe levels of noise, exposure, effects of noise on their health and use of personal protective equipment. Approved hearing protection equipment (noise attenuating devises) will be available to every employee working in areas where continuous noise levels exceed 85 decibels (dB). To be effective, ear protection, must be properly fitted and employees will be instructed in their use and care.(APPENDIX E Hearing and Sight Conservation Program)


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VII. FUELING Where flammable liquids are used, employees will be trained to deal with spillage during fueling operations. Gasoline and fuel oil storage containers will be inspected quarterly and all applicable licenses shall be maintained. Employees must be aware that an open flame or light near any fuel is prohibited when fueling or the transfer of fuel is occurring. NO SMOKING signs will be posted in conspicuous places. VIII. PIPING SYSTEMS Substances that are transported through piping need to be identified by color or labeling. Signs must be posted identifying the substance being transported through the pipes as to whether it is hazardous and where turn off valves, connection and outlets are located. All tags used for labeling will be of a durable material and distinguishable and clearly written print. When non-potable water is piped through a facility, outlets or taps, notices will be posted to alert employees that is unsafe and not to be used for drinking, washing or personal use. When pipelines are heated by electricity, steam or other external sources, warning signs or tags placed at the unions, valves or other serviceable points will be attached to the system. IX. COMPRESSORS AND COMPRESSED AIR All compressors must be equipped with pressure relief valves and pressure gauges. All compressor air intakes must be installed and equipped to ensure that only clean, uncontaminated air enters the compressor. Every air receiver must be provided with a drain pipe and valve at the lowest point for the removal of accumulated oil and water. Compressed air receivers must be periodically drained of moisture and oil. All safety valves shall be tested frequently and at regular intervals to determine whether they are in good operating order. A current operating permit issued by the Division of Occupational Safety and Health shall be maintained. The inlet of sir receivers and piping systems must be kept free and clear. X. HOIST AND AUXILIARY EQUIPMENT Every overhead electrical hoist shall be equipped with a limit device to stop the hook travel at its highest and lowest points of safe travel. Check these limits without a load to ensure the device is working correctly. Each hoist should automatically stop and hold any load up to 125 percent of its rated load if its actuating force is removed. Check this periodically under controlled conditions. Make sure that the rated load of each hoist is legibly marked and visible to the operator. Stops should be provided at the safe limits of travel for trolley hoists. The controls of hoists should be plainly marked to indicate direction of travel or motion. Every cage-controlled hoist must be equipped with an effective warning device. Close-fitting guards or other suitable devices should be installed on hoists to assure hoist rope will be maintained in the sheave grooves. All hoist chains or ropes must be of sufficient length to handle the full range of movement for the application, while maintaining two full wraps on the drum at all times. All nip points or contact points between hoist ropes and sheaves which are permanently located within seven feet of the floor,


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the ground or working platform must be guarded. It is prohibited to use chains or rope slings that are wrinkled or twisted. The operator should avoid carrying loads over people. Only employees who have been trained in the proper use of hoists are allowed to operate them. XI. VENTILATION In the operation of any facility ventilation system, there needs to be a design that integrates several systems of control, which will expel contaminates and provide clean air. The system must take into consideration the volume and velocity that will be needed to successfully remove contaminates. The system must not fail in the case of an emergency situation where two contaminates are exposed to each other when a fire or explosion occurs. In the design of the system, clean out ports or doors that are provided at intervals will not exceed 12 feet in all horizontal runs of exhaust ducts. The system must be operational so that it will not offset the functions of other operations. XII. ERGONOMICS With the introduction of computers into the workplace, new areas of physical debilitation have been recognized. These new potential hazards have required a redesigning of both the workplace and how employees work. A set of standards will be developed and practiced with this new technology, which will include:

1) Furniture will be adjustable, positioned and arranged to minimize strain on all parts of the body.

2) The glare of a computer screen will be adjusted by the use of glare screens to prevent

eyestrain. 3) Repetitive motions can harm the back, shoulders, neck, wrists, and other parts of the body.

Employees will not proceed with a task when they are physically impaired. 4) Each employee will be entitled to a rest break. We recommend that the break is taken in

order to prevent injury.

XIII. SAFETY POSTERS Our company is required to post certain employment related information. This required information

is maintained on a bulletin board by (give specific location) where employees can find the following required posters:

Various State and Federal orders regulating the wages, hours, and working conditions in certain industries

Payday notice Anti-Discrimination Poster Equal Employment Opportunity is the Law (EEOC form) OSHA Safety and Health Protection on the Job Notice of Workers Compensation Carrier Notice to Employees: Unemployment Insurance and Disability Insurance Notice: Employee Polygraph Protection Act Access to Medical and Exposure Records


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Notice to Employees: Time off to vote In addition to the above listed notices, a copy of this injury prevention program, a log and summary of Occupational Injuries and Illnesses, a copy of the Companys code of Safe Work Practices, and a Fire Prevention and Evacuation Plan will be posted.

XIV. LICENSES AND PERMITS In addition to other postings required by law, the Company maintains a copy of all necessary

business licenses, permits, and notices required by the National Labor Relations Board or other governmental bodies, notices of citations during abatement periods, and other required information which are posted during the appropriate times.

XV. WALKWAYS All aisles, passageways and walkways must be kept clear. Also, aisles and passageways should be

clearly marked. Wet surfaces must be covered and non-slip material and all holes properly covered or marked with warning guards. All spills must be cleaned up immediately, and a caution sign placed on all wet and drying surfaces.

In cases of passageways used by forklifts, vehicles or other machinery, walkways should be clearly marked and signs posted warning pedestrians of vehicular use.

Equipment must be properly stored so that sharp edges do not protrude into walkways. Changes in elevation must be clearly marked, as must passageways near dangerous operations like welding, machinery operation or painting. If there is a low ceiling, a warning sign must be posted. If the walkway or stairway is more then 30 inches or 4 steps above ground, it must have a guardrail.

If an employee is aware of any breach of these standards, please inform your immediate supervisor. XVI. FLOOR AND WALL OPENINGS Be careful when working near floor and wall openings. All floor openings should be guarded by a

cover, guardrail, or equivalent barrier on all sides except at the entrance to stairways and ladders. Freight-lifts should have proper side rails permanently installed and landings should be marked clearly with a yellow warning border. Toe boards must be installed around the edges of a permanent floor opening if; persons can pass underneath opening, there is moving machinery underneath, or there is equipment which falling materials could create a hazard. Skylights must be able to withstand at least 200 pounds of pressure. Glass used in windows, doors and walls (including block glass) must be able to withstand a human impact and if required by code, be shatterproof safety glass. Before beginning work at a new location, inspect it to ensure that all floor openings, which must remain open, such as floor drains, are covered with grates or similar covers. In roadways and driveways, covers with capacity to carry a truck rear axle load of at least 20,000 pounds must protect all manholes and trenches. In office buildings, fire resistive construction required that the doors and hallway closures be properly rated and be equipped with self closing features. Be sure that there are at least two fire emergency exits accessible from your location at all times.


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XVII. TOOL MAINTENANCE Faulty or improperly used hand tools are a safety hazard. All employees shall be responsible for ensuring that tools and equipment (both company and employee owned) used at their workplace are in good condition. Hand tools such as chisels, punches, etc., which develop mushroom heads during use, must be reconditioned or replaced as necessary. Broken and fractured handles on hammers, axes and similar equipment must be replaced promptly. Worn or bent wrenches should be replaced regularly. Appropriate handles must be used on files and similar tools. Appropriate safety glasses, face shields, etc., must be worn while using hand tools or equipment which might produce flying material or be subject to breakage. Eye and face protection must be worn when driving in tempered studs or nails. Check your tools often for wear or defects. Jacks must be checked periodically to assure they are in good working condition. Tool handles must be wedged tightly into the head of tools. Tool cutting edges should be kept sharp enough so the tool will move smoothly without binding or sloping. When not in use, tools should be stored in a dry secure location. XVIII. LADDERS Check ladders each and every time before you climb. Ladders should be maintained in good condition: joint between steps and side rails should be tight; hardware and fittings securely attached; and movable parts operating freely without binding or undue play. Non-slip safety feet are provided on each ladder. Ladder rungs and steps should be free of grease and oil. Employees are prohibited from using ladders that are broken, missing stops, rungs or cleats, or that have broken side rails or other faulty equipment or parts. It is prohibited to place ladders in front of door openings toward the ladder except when the door is blocked open, locked or guarded. Placing ladders on boxes, barrels or other unstable bases to obtain additional height is strictly prohibited. Face the ladder when ascending or descending. Be careful when you climb a ladder. Do not use the top step of an ordinary ladder as a step. When portable rung ladders are used to gain access to elevated platforms, roofs, etc., the ladder must always extend at least three feet above the elevated surface. It is required that when portable rung or cleat type ladders are used, the base must be so placed that slipping will not occur, unless it is latched to otherwise held in place. All portable metal ladders must be legibly marked with a sign reading CAUTION Do Not Use Around Electric Equipment. Using ladders as guys, braces, skids, gin poles, or anything other than their intended purposes is strictly prohibited. Only adjust ladders while standing at a base (not while standing on the ladder or from a position above the ladder). Metal ladders should be inspected for tears and signs of corrosion. Rungs of ladders should be uniformly spaced at 12 inches center to center. XIX. COMBUSTIBLE MATERIALS All combustible materials must be stored in covered metal receptacles and removed from the work site promptly. Proper storage to minimize the risk of fire, including spontaneous combustion, must


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be practiced. Only approved containers are to be used for the storage and handling of flammable and combustible liquids. All connections on drums and combustible liquid piping, vapor and liquid must be kept tight. All flammable liquids should be kept in closed containers when not in use. Bulk drums of flammable liquids must be grounded and bonded to containers during dispensing. Storage rooms for flammable and combustible liquids must have explosion proof lighting and should have mechanical or gravity ventilation. Liquefied petroleum gas must be stored, handled, and used in accordance with safe practices and standards. NO SMOKING signs must be posted on liquefied petroleum gas tanks. Liquefied petroleum storage tanks should be guarded to prevent damage from vehicles. All solvent waste and flammable liquids should be kept in a fire resistant covered container until they are removed from the work site. NO SMOKING rules will be enforced in areas involving storage and use of hazardous materials. NO SMOKING signs are posted where appropriate in areas where flammable or combustible materials are used and/or stored. Safety cans must be used for dispensing flammable or combustible liquids at point of use. All spills of flammable and combustible liquids must be cleaned up promptly. Storage tanks should be adequately vented to prevent the development of excessive vacuum or pressure as a result of emptying or atmosphere temperature changes. Storage tanks are equipped with emergency venting that will relieve excessive internal pressure caused by fire exposure. XX. FIRST AID KITS First aid kits and required contents are maintained in a serviceable condition. Unit-type kits have all items in the first aid kit individually wrapped, sealed, and packaged in comparable sized packages. The commercial or cabinet kits do not require all items to be individually wrapped and sealed but only those which must be kept sterile. Items such as scissors, tweezers, tubes of ointments with caps or rolls of adhesive tape, need not be individually wrapped, sealed, or disposed of after a single use or application. Individual packaging and sealing shall be required only for those items that must be kept sterile in a first aid kit. Where eyes or body of any person may be exposed to injurious chemicals and/or materials, suitable facilities for quick drenching or flushing of the eyes and body are provided, within the work area, for immediate emergency use. A poster is fastened and maintained either on or in the cover of each first aid kit and at or near all phones plainly stating the phone numbers of available doctors, hospitals, and ambulance services. XXI. ENVIRONMENTAL CONTROLS All locations will have an MSDS manual listing chemicals used at the location, their respective MSDS sheets and emergency first aid instructions. HAZMAT procedures should also be included in the MSDS manual. When fibrous materials such as asbestos are being handled, the necessary precautions must be taken to protect employees from the material. The material must be labeled, along with signs conspicuously posted that these materials are being used in the area. Employees should be aware of


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effective methods used to prevent emission of airborne asbestos fibers, silica dust and other similar hazardous materials. Some of the recommended methods for controlling the emission of these materials are using water and vacuuming, rather then blowing and sweeping the material. Machinery such as grinders, saws and other tools that produce a fine airborne dust must be vented to an industrial collector or central exhaust system. Any ventilation system should be designed and operated at an airflow and volume necessary for proper application and effectiveness. In the design of the ventilation system the ducts and belts must be free of obstructions and slippage. As with all operations, there must be written standards on the procedures for the equipment, description of the job task, usage of the protective equipment provided, such as the selection and use of respirators, and when they are needed. Any water that is provided to an employee throughout the facility should be clearly identified as water for drinking, washing or cooling. All restrooms must be kept clean and sanitary. Employees should be screened before taking positions that may expose them to hazards they are not physically capable of handling. Employees who take an assignment which requires physical labor must be trained to lift heavy loads properly so as not to damage themselves physically. If the work assignment involved dealing with equipment that produces ultra-violet radiation, employees must be properly protected or given the correct protective clothing. Employees posted to an assignment on a roadway where there is heavy traffic must be given the designated protective clothing (bright colored traffic orange warning vests) and safety training regarding the hazards of this job.


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CHAPTER 3 CHEMICAL SAFETY

I. INTRODUCTION The objective of this chapter is to provide guidance to all employees who use hazardous material so that they may perform their work safely. Many of these materials are specifically explosive, corrosive, flammable, or toxic; they may have properties that combine these hazards. Many chemicals are relatively non-hazardous by themselves but become dangerous when they interact with other substances, either in planned operations or by accidental contact. All employees must be aware of the hazards involved when working with chemicals and the remedies that need to be used when an accident does occur. A training program will provide instructions on how to handle the chemical being used and first aid to be applied to victims of chemical exposure. First aid and caution signs will be conspicuously posted to alert individuals on a constant basis. Charts identifying the chemicals utilized in the workplace, their symptoms and effects must be posted. Workers must know the acceptable levels of exposure to a chemical and what safety systems must be in place when working with a chemical. Staff should be aware of new chemical products which may be available that are less harmful, and they must ensure that facilities are adequately ventilated when using chemicals on the premises. Before using a specific chemical, safe handling methods must always be reviewed. II. HAZCOM PLAN On May 25, 1986 the Occupational Safety and Health Administration (OSHA) placed in effect the requirements of a new standard call Hazard Communication (29CFR 1910-1200). This standard established requirement ensures that chemical hazards in the workplace are identified and that this information, along with information on protective measures, is transmitted to all affected employees. This section describes how our Company and our employees are informed of the potential chemical hazards in their work area so they can avoid harmful exposures and safeguard their health. Components of this program include labeling, preparing a Material Safety Data Sheet (MSDS), the right to know and training. Supervisors must:

1) Identify hazards and hazardous materials for respective work areas.

2) Ensure hazards are properly labeled.

3) Obtain/maintain copies of material safety data sheets, as required, of each hazardous material.

4) Have written Hazard Communication Program available to all employees.

5) Provide hazard-specific training to employees.

Employees must:

1) Attend safety meetings.


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2) Perform operation in safe manner.

3) Notify supervisors immediately of any safety hazards or injuries.

4) If ordering material, identify all hazardous chemicals.

The Company designed Safety Officer must:

1) Develop and keep updated a written Hazard Communication Program.

2) Maintain a central file of MSDS.

3) Review and update stock safety labels.

4) Provide generic training programs.

5) Assist supervisors in developing hazard-specific training programs.

6) Oversee the Hazard Communication Stand written policy and implementation plans.

7) Alert on site sub-contractors and contractors to hazardous materials in work areas.

8) Alert on site sub-contractors and contractors that they must provide to the employees information on hazardous materials they bring to the work site.

The number of hazardous chemicals and the number of reactions between them is so large that prior knowledge of all potential hazards can not be assumed. Therefore, when the chemical properties of a material are not fully known, it should be assumed hazardous and used in as small quantities as possible to minimize exposure and thus reduce the magnitude of unexpected events. All employees must follow general safety precautions when working with chemicals. These precautions are:

1) Keep work area clean and orderly.

2) Use necessary safety equipment.

3) Carefully label every container with the identity of its contents and appropriate hazard warnings.

4) Store incompatible chemicals in separate areas.

5) Substitute less toxic materials whenever possible.

6) Limit the volume of volatile or flammable material to the minimum needed for short

operation periods.


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7) Provide means of containing the material if equipment or containers should break or spill their contents.

8) Follow the requirements of this manual, if systems that can generate pressure or are operated

under pressure are involved. 9) Provide a back up method of shutting off power to a heat source if any hazard is involved. 10) Obtain and read the MSDS.

NFPA 704 provides a readily recognized, easily understood system for identifying specific hazards and their severity by using the NFPA Hazard Diamond. This diamond will be displayed in any of our facilities that manufacture, process, use or store hazardous materials. Interpretation of the diamond is as follows BLUE HEALTH

4-Deadly even the slightest exposure to this substance would be life threatening. Only specialized protective clothing, for these materials, should be worn.

3-Extreme Danger serious injury would result from exposure to this substance. Do not expose any body surface to these materials. Full protective measures should be taken. 2-Dangerous exposure to this substance would be hazardous to health. Protective measures are indicated.

1-Slight Hazard irritation or minor injury would result from exposure to this substance. Protective measures are indicated.

0-No Hazard exposure to this substance offers no significant risk to health. RED FLAMMABILITY

4-Flash Point Below 73 degrees F this substance is very flammable, volatile or explosive depending on its state. Extreme caution should be used in handling or storing these materials.

3-Flash Point Below 100 degrees F flammable, volatile or explosive under almost all normal temperature conditions. Exercise great caution in storing or handling these materials.

2-Flash Point Below 200 degrees F moderately heated conditions may ignite this substance. Caution procedures should be employed in handling. 1-Flash Point Above 200 degrees F this substance must be preheated to ignite. Most combustible solids would be in this category.

0-Will Not Burn substances that will not burn. YELLOW INSTABILITY

4-May Detonate substances that are readily capable of detonation or explosion at normal temperatures and pressures. Evacuate area if exposed to heat or fire.

3-Explosive substances that are readily capable of detonation or explosion by a strong initiating source, such as heat, shock or water. Monitor from behind explosion resistant barriers.

2-Unstable violent chemical changes are possible at normal or elevated temperatures and pressures. Potentially violent or explosive reaction may occur when mixed with water. Monitor from a safe distance.


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1-Normally stable substances that may become unstable at elevated temperatures and pressures or when mixed with water. Approach with caution.

0-Stable substances will remain stable when exposed to heat, pressure or water. WHITE SPECIAL HAZARDS

This information is conveyed by the use of symbols which represent the special hazard. Some facilities use the white symbol to convey personal protective equipment requirements. You may see pictures of PPE here.

III. HAZARDOUS CHEMICAL EXPOSURES The Company will conduct a yearly training program on handling, hazards, storage, exposure risks, symptoms of chemical exposure and first aid. The annual training program will also be part of any new employee training. There must also be follow up training sessions regarding any new chemical or processes that may be initiated by the company. Follow up training sessions act as a reinforcement of safety standards that need to be followed on a daily basis. In the training program, employees will learn acceptable levels of chemical exposures, proper storage and labeling of chemicals, and the use of protective clothing and equipment for handling chemicals. They will also learn about potential fire and toxicity hazards, when not to have a chemical in a confined area, or to store in closed containers, the use of eye wash stations and safety showers, and the necessary posting of open and dangerous areas. It is important that an employee recognize the Threshold Limit Values or Permissible Exposure Limits of airborne contaminants and physical agents in the workplace A procedure manual or set of instructions must be part of the program, with periodic inspections that clearly indicate whether an employee may be mishandling a chemical or endangering himself or others. Part of the manual or procedures must establish a standard of when and how to deal with chemical spills, neutralizing and disposing of spills or overflows. This procedure must also be posted in an area that is easily accessible for reference usage. Specialized first aid training and equipment will be routine in any facility where chemicals are used. Employees must know how to handle equipment in emergency situations, what equipment needs to be used and whether the equipment is adequate for the situation. With a first aid program an employee will recognize when a problem may be occurring by exposure to a chemical. Symptoms may include headaches, nausea, dermatitis problems and potentially other physical reactions as a result of using solvents or chemicals. Ventilation is another major factor in facility design and maintenance. Whether by natural means or mechanical, the system must be designed to control dust, fumes, solvents, gases, smoke or vapors which may be generated in the workplace. It is also important that a medical or biological monitoring system be in operation as part of the safety standard. If internal combustion engines are in use in the facility, or if there is a chance of leakage or mixture with a chemical that could create a toxic gas, atmospheric gas levels must be


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monitored. If toxic chemicals are used and stored in the facility, they should be located in an isolated area to guarantee safety.

IV. TASK EVALUATION Each task that requires the use of chemicals must be evaluated to determine the potential hazards associated with the work. This hazard evaluation must include the chemical or combination of chemicals that will be used in the work, as well as other materials that will be used near the work. If a malfunction during the operation has the potential to cause serious injury or property damage, an Operational Safety Procedure (OSP) must be prepared and followed. Operations must be planned to minimize the generation of hazardous wastes. Additional, unused chemicals should be recycled. In preparing an Operational Safety Procedure, the following steps are required:

1) Select and define the task to be analyzed, 2) Break the task down into observable steps.

3) Identify hazards in each step of the process

4) Identify all PPE required for the entire process

V. GENERAL RESPONSIBILITIES

1) It is the responsibility of employees and all who use the Companys facilities to understand the properties of the chemicals with which they will work and to follow all precautions that apply to each specific task.

2) When faced with an unexpected malfunction, injury or damage, employees are expected to

choose a course of action that provides the most protection to themselves and to others in the area.

3) Each employee is expected to report to their supervisor an unsafe condition seen in the area

that would not permit him or her to work safely.

4) Supervisors and Risk Managers assist employees in following safe work practices by providing information on the hazardous properties of materials, recommending methods for controlling the hazards of specific operations and by monitoring the work environment.

a. Supervisors must instruct their personnel about the potential hazards involved in the work,

proper safety precautions to follow, possible consequences and emergency procedures to use if an accident should occur. It is also their responsibility to ensure that the protective equipment needed to work with the chemicals is available.


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VI. LABELS All containers (including glassware, safety cans, and plastic squeeze bottles) must have labels that identify their chemical contents. Labels should also contain information on the hazards associated with the use of the chemical. Labels must be legible at all times. VII. CHEMICAL STORAGE The separation of chemicals (solids or liquids) during storage is necessary to reduce the possibility of unwanted chemical reactions caused by accidental mixing. Chemicals must not be stored in the same refrigerator used for any type of food storage. Storage units must follow OSHA guidelines stated in CFR, section 1910.106. VIII. EMERGENCIES In case of an emergency, consider any of the following actions if appropriate:

1) Evacuate people from the area.

2) Isolate the area.

3) If the material is flammable, turn off ignition and heat sources.

4) Call the Fire Department or 911 for assistance.

5) Wear all necessary Personal Protective Equipment.

6) Pour Sorb-all or appropriate neutralizing agent on spill.

7) Clean up; place waste in proper bag or waste disposal container for disposal. IX. DISPOSAL OF CHEMICALS All Company employees, participating guests and visitors using hazardous chemicals are responsible for disposing of chemicals safely:

1) Federal and State regulations mandate strict disposal procedures for chemicals. To comply with these regulations all personnel using Company facilities must observe these procedures

2) Routine disposal of chemicals:

a) In the general disposal of hazardous chemicals to the sanitary sewer, is not permitted. The personnel designated by the Company will advise on the proper disposal of chemical wastes.

b) In using chemical waste storage containers, certain procedures must be observed, as listed

below.

c) Incompatible chemicals must not be mixed in the same container.


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d) Waste oils must be collected in 55 gallon drums. Disposal solids and explosive materials must be stored in separate containers.

3) The following requirements must be met as a condition for pickup and disposal of chemicals by the Company Risk Manager:

a) Chemicals must be separated into compatible groups. b) Dry materials must be securely contained in plastic bags and over packed in a cardboard

box. Packages that are wet or have sharp protruding objects will not be accepted for pick up.

c) Unknown chemicals will require special handling. The responsible department must

make every effort to identify the material that is to be disposed of. If all the users attempts to identify the waste chemicals have failed, the Rick Manager will make the decision as to how to proceed.

d) Each breakable container must be properly boxed. Place all bottles in plastic bags, then

place in a sturdy container and use an adsorbent cushioning material that is compatible with the chemicals.

e) Each primary container must be labeled with contents, amount, physical state and the

percentage breakdown of a mixture.

f) Each box must have a complete list of contents or description.

g) For safety purposes, boxes must be of a size and weight so that one person can handle them. Boxes that exceed 45 pounds or 18 inches on a side cannot be safely handled by one person and will not be acceptable for pick up.

4) General Housekeeping rules:

a. Maintain the smallest possible inventory of chemicals to meet you immediate needs.

Periodically review your stock of chemicals on hand.

b. Ensure that storage areas or equipment containing large quantities of chemicals are secure from accidental spills.

c. Rinse empty bottles that contain acids or inflammable solvents before disposal

d. Recycle unused chemicals whenever possible.

e. DO NOT:

1) Place hazardous chemicals in salvage or garbage receptacles.


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2) Pour chemicals into the ground. 3) Dispose of chemicals through the storm drainage system. 4) Dispose of highly toxic, malodorous, or lachrymatory chemicals down sinks or sewer drains.


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CHAPTER 4

ELECTRICAL SAFETY I. INTRODUCTION It is the policy of this Company to take every reasonable precaution in the performance of work to protect the health and safety of employees and the public, and to minimize the probability of damage to property. The electrical safety requirements contained in this chapter are regulations set forth by this organization. II. RESPONSIBILITIES All personnel are responsible for all aspects of safety within their own group. The Company designated Risk Manager is responsible for providing information, instruction and assistance where appropriate. Individual employees are responsible for their own and their co-workers safety. This means that each employee should:

1) Become acquainted with all potential hazards in the area in which they work.

2) Use and follow the appropriate standards, procedures and hazard control methods.

3) Never undertake a potentially hazardous operation without consulting with appropriate supervision.

4) Stop any operation you believe to be hazardous.

5) Notify your supervisor of any condition or behavior that poses a potential hazard.

6) Wear all appropriate Personal Protective Equipment.

7) Immediately report any occupational injury, illness or near miss to your immediate

supervisor. Supervisors and supervisory positions should:

1) Develop an attitude and awareness of safety in the people supervised and seeing that individuals safety responsibilities are fully carried out.

2) Maintain a safe work environment, and take corrective action on any potentially hazardous

operation or condition.

3) Ensure that the personnel you direct are knowledgeable and trained in the tasks they are asked to perform.


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4) Ensure that safe conditions prevail in the area and that everyone is properly informed of the areas safety regulations and procedures.

5) Ensuring that contract personnel are properly protected by means of instructions, signs,

barriers, or other appropriate resources.

6) Ensuring that no employee is assigned to potentially hazardous work appears to be fatigued, injured, emotionally disturbed or under the influence of alcohol or drugs (prescription, over the counter medicinal or otherwise).

Management shall:

1) Be responsible for being aware of all potentially hazardous activities within the area of responsibility.

2) Assign responsibility or delegate authority for performance of any function, but remains

accountable to higher management for any oversight or error that leads to injury, illness or damage to property.

III. GENERAL PROCEDURES It is the policy of this Company to follow the fundamental principles of safety, which are listed below: A clear understanding of these principles will improve safety of working with or around electrical equipment.

1) Practice proper housekeeping and cleanliness. Every employee is responsible for keeping a clean area and every supervisor is responsible for ensuring that his or her area of responsibility remains clean.

2) Identify hazards and anticipate problems. Do not hesitate to discuss any situation or question

with your supervisor and co-workers.

3) Resist hurry up pressure. Pressures should not cause you to bypass thoughtful consideration and planned procedures.

4) Consider safety to be an integral part of the design process. Protective devises, warning

signs, and administrative procedures are supplements to good design but can never fully compensate for its absence. Completed designs should include provisions for safe maintenance.

5) Maintenance procedures and schedules for servicing and maintaining equipment and

facilities, including documentation of repairs, removals, replacements, and disposal, should be established.


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6) Document your work. An up to date set of documentation adequate for operation, maintenance, testing, and safety should be available to anyone working on potentially hazardous equipment. Keep drawings and prints up to date. Dispose of obsolete drawings and be certain that active file drawings have the latest corrections.

7) Have designs reviewed. All systems and modifications to systems performing a safety

function or controlling a potentially hazardous operation must be reviewed and approved at the level of project engineer or above.

8) Have designs and operation verified. All systems performing safety functions or controlling

hazardous operations must be periodically validated by actual test procedures at least once a year.

9) Test equipment safely. Tests should be made when the electrical equipment is de-energized,

or at most, energized with reduced hazard.

10) Know emergency procedures. All persons working in areas of high hazard (with high-voltage power supplies, capacitor banks, etc.) must be trained in emergency response procedures, including cardiopulmonary resuscitation (CPR).

IV. WORKING WITH ENERGIZED EQUIPMENT This section contains safety requirements that must be met in constructing electrical equipment and in working on energized electrical equipment. Special emphasis is placed on problems associated with personnel working on hazardous electrical equipment in an energized condition. Such work is permissible, but only after extensive effort to perform the necessary tasks with the equipment in a securely de-energized condition has proven unsuccessful, or if the equipment is so enclosed and protected that contact with hazardous voltages is essentially impossible. The following definitions are used in this discussion of electrical safety: 1) Authorized Person: An individual recognized by management as having the

responsibility for and expertise to perform electrical procedures in the course of normal duties. Such individuals are normally members of electronic or electrical groups.

2) Back up Protection: A secondary, redundant, protective system provided to de-energize a

device system or facility to permit safe physical contact by assigned personnel. A backup protective system must be totally independent of the first line protection and must be capable of functioning in the event of total failure of the first line protective system.

3) Companion: A co-worker who is cognizant of potential danger and occasionally checks the

other worker.

4) Electrical Hazard: A potential source of personnel injury involving, either directly or indirectly, the use of electricity.


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5) Direct Electrical Hazard: A potential source of personal injury resulting from the flow of electrical energy through a person (electrical shock and burns).

6) Indirect Electrical Hazard: A potential source of personal injury resulting from electrical

energy that is transformed into other forms of energy (e.g., radiant energy, such as light, heat or energetic particles; magnetic fields, chemical reactions, such as fire, explosions, the product of noxious gases and compounds; involuntary muscular reactions).

7) First Line Protection: The primary protective system and or operational procedure provided

to prevent physical contact with energized equipment.

8) General Supervision: The condition that exists when an individual works under a supervisors direction but not necessarily in the continuous presence of the supervisor.

9) Grounding Point: The most direct connection to the source of a potential electrical hazard

such as the terminals of a capacitor. A yellow circular marker must indicate such a point.

10) Grounds, Electrical: Any designated point with adequate capacity to carry any potential currents to earth. Designated points may be building columns or specially designed ground network cabling, rack, or chassis ground. Cold water pipes, wire easy and conduits must not be considered electrical grounds.

11) Grounds, Massive: Large areas of metal, concrete, or wet ground that make electrical

isolation difficult or impossible.

12) Implied Approval: Approval is implied when a supervisor, knowing the qualifications of an individual, assigns that individual a task or responsibility for, a devise, system or project.

13) Qualified Person: An individual recognized by management as having sufficient

understanding of a devise, system or facility to be able to positively control any hazard it may present.

14) Safety Watch: An individual whose sole task is to observe the operator and to quickly de-

energize the equipment, using a crash button, or circuit breaker control in case of an emergency, and to alert emergency personnel. This person should have basis CPR certification.

V. GENERAL SAFETY RULES 1) All operations are to be conducted with the equipment in a positively de-energize state. All external sources of electrical energy must be disconnected by some positive action (e.g. lock out breaker) and with all internal energy sources rendered safe. This is for minimum hazard situations. (Mode 1).

2) All manipulative operations (such as making connections or alterations to or near normally energized components) are to be conducted with the equipment in the positively de-energized state. Measurements and observations or equipment functions may then be conducted with


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the equipment energized and with normal protective barriers removed (Mode 2). This is for moderate to severe hazard situations, depending on the operating voltage and energy capabilities of the equipment.

3) When manipulative, measurement and observation operations are to be conducted with the

equipment fully energized and with the normal protective barriers removed is permitted only when fully justified and should be conducted under the closest supervision and control (Mode 3). One knowledgeable person should be involved in addition to the worker. Written permission may be required.

4) An up to date set of instructions for operation, maintenance, testing and safety should be

provided and made readily available to anyone working on hazardous equipment.

5) As many tests as practicable should be made on any type of electrical equipment in the un-energized condition, or at most, energized with reduced hazard.

6) All covering, clothing and jewelry that might cause hazardous involvement must be removed.

7) Adequate and workable lockout/tagout procedures must be employed.

8) A person in a hazardous position who appears to be fatigued, ill, emotionally disturbed, or

under the influence of alcohol and/or drugs (medicinal or otherwise) must be replaced by a competent back up person, or the hazardous work must be terminated.

9) Supervisors and workers must be encouraged to make the conservative choice when they are

in doubt about a situation regarding safety.

10) Training sessions and drills must be conducted periodically to help prevent accidents and to train personnel to cope with any accidents that may occur. CPR instruction must be included.

11) An emergency OFF switch, clearly identified and within easy reach of all high hazard

equipment, should be provided. Also, this switch may be used to initiate a call for help. Resetting an emergency OFF switch must not be automatic but must require an easily understandable overt act.

12) Automatic safety interlocks must be provided for all access to high hazard equipment. Any

bypass of such an interlock should have an automatic reset, display conspicuously the condition of the interlocks, and ensure that barriers can not be closed without enabling the interlock.

13) Communication equipment (e.g., fire alarm box, telephone) should be provided near any

hazardous equipment. Its location should be clearly marked to ensure that the person requesting assistance can direct the people responding to a call for help to the emergency site quickly.


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14) Any component that in its common use is non-hazardous, but in its actual use may be hazardous, must be distinctively colored and/or labeled. (An example might be a copper pipe carrying high voltage or high current.)

15) Periodic tests of interlocks to ensure operability must be performed and documented at least

yearly. VI. LOCKOUT/TAGOUT PROCEDURES All machinery and equipment capable of movement must be de-energized or disengaged and locked out during cleaning, servicing, adjusting or setting up operations. The locking out of the control circuits in lieu of locking out main power disconnects is prohibited. All equipment control valve handles must be provided with a means for locking out. The lockout procedure required that stored energy be released or blocked before equipment is locked out for repairs. Appropriate employees may be provided with individually keyed personal safety locks. Employees are required to keep personal control of their keys while they have safety locks in use. Employees must check the safety of the lockout by attempting a start up after making sure no one is exposed. When the power disconnect does not also disconnect the electrical control circuit, the appropriate electrical enclosures must be identified. The control circuit can also be disconnected and locked out. VII. ELEVATED LOCATIONS Any person working on electrical equipment on a crane or other elevated location must take necessary precautions to prevent a fall from reaction to electrical shock or other causes. A second person, knowledgeable as a safety watch, must assume the best possible position to assist the worker in case of an accident VIII. SAFE PRACTICES

1) Cable Clamping a suitable mechanical strain relief device such as a cord grip, cable clamp or plug must be used for any wire or cable penetrating an enclosure where external movement or force can stress on the internal connection. Grommets, adlets or similar devices must be used as a strain relief.

2) Emergency lighting there must be an emergency lighting system that activates when

normal power fails in Class C conditions. 3) Flammable and Toxic Material Control - The use of flammable or toxic material must be

kept to a minimum. When components with such fluids are used, a catch basin or other approved method must be provided to prevent the spread of these materials.

4) Isolation - Covers and enclosures must isolate all sources of dangerous voltage and current.

Access to lethal circuits must be either via screw on panels, each containing no less than four screws or bolts, or by interlocking doors. The frame or chassis of the enclosure must be connected to a good electrical ground with a conductor capable of handling any potential fault current.


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5) Overload protection Overload protection and well marked disconnects must be provided. Local off controls must be provided on remote controlled equipment

6) All disconnects and breakers should be clearly labeled as to which loads they control. 7) Power all ac and dc power cabling to equipment not having a separate external ground but

having wire to wire or wire to ground voltage of 50 volts or more must carry a ground conductor unless cabling is inside an interlocked enclosure, rack, grounded wire way or conduit or feeds a commercial double insulated or UL approved device.

8) Ratings All conductors, switches, resistors etc. should be operated within their design

capabilities. Pulsed equipment must not exceed either the average, the rms, or the peak rating of components. The equipment should be de-rated as necessary.

9) Safety Grounding Automatic discharge devices must be used on equipment with stored

energy of five joules or more. Suitable and visible manual grounding devices must also be provided to short to ground all dangerous equipment while work is being performed.

10) Primary Disconnect a means of positively disconnecting the input must be provided. This

disconnect must be clearly marked and located where the worker can easily lock or tag it out while servicing the power supply. The lock out device must have a removable key, unless the switch or breaker is in the off position.

11) Exposed wiring and cords with frayed or deteriorated insulation must be repaired or replaced. 12) Flexible cords and cables must be free of splices or taps. 13) The location of electrical power lines and cables (overhead, underground, under floor, other

side of walls) must be determined before digging, drilling or similar work. 14) All openings in electrical enclosures and fittings must have appropriate covers, plugs or

plates. All switches, receptacles or junction boxes must be provided with tight fitting covers or plates.

15) All employees who regularly work on or around energized electrical equipment or lines will

be instructed in CPR. Employees will be trained on how to work on energized lines or equipment over 6M volts.


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CHAPTER 5

FIRE SAFETY I. INTRODUCTION Policy and procedures for fire safety takes into account the special fire hazards for all areas of the Company. The protection of high value property, the safety of employees and visitors is also a major concern. This chapter covers the fire safety responsibilities of all employees and sets forth the fire safety rules and procedures. In the event of a fire, all employees should:

1. Remove personnel from immediate danger. 2. Sound the fire alarm.

II. BASIC PROCEDURES It is essential that all personnel become familiar with the fire safety rules and to remember:

1) Saving a life comes first and foremost. 2) The preservation of property is secondary. 3) Panic is the greatest danger in most disasters. 4) Never shout Fire. 5) Dont alarm others by excited motions, always appear calm and move with assurance. 6) Prevention is the best guarantee against disaster. 7) Early detection and prompt reporting means early control. 8) Know evacuation routes and above all know what to do in an emergency. 9) Do not use elevators during an emergency. 10) Know where the fire extinguishers are located.

III. FIRE DRILLS/EVACUATIONS Fire Drills are to be held monthly and documented (APPENDIX F-Fire Drill Documentation). The Company will designate two employees in each area to be responsible for holding the fire drills and checking the building or area to be certain that all employees and visitors have been evacuated. This designee will also be responsible for posting and updating all evacuation plans for their area. An evacuation plan will include:

1. Fire Evacuation route. 2. Location of Fire Extinguishers. 3. Location of pull boxes. 4. Designated areas outside the building for gathering. 5. Main Water source. 6. Main Electrical source. 7. Fire Doors. 8. Main gas source. 9. Any other items or equipment related to a fire.


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A fire safety Inspection will be done at least quarterly. Documentation (APPENDIX G-Fire Safety Inspection Checklist)) will be kept for a period of time designated by the company. IV. FIRE EXTINGUISHERS The Company has determined the type of fire extinguishers in each area by the type of fires that could possibly occur in that area. There are four types of fires:

CLASS A fires involving ordinary combustible materials such as paper, wood, cloth and some rubber and plastic materials.

CLASS B fires involving flammable or combustible liquids, flammable gasses, grease or similar material and some rubber and plastic materials.

CLASS C fires involving energized electrical equipment where safety to the employee requires the use of electrically nonconductive extinguishing media.

CLASS D fires involving combustible metals such as magnesium, sodium and potassium. Each fire extinguisher is marked for the type of fire it will extinguish. In addition, each extinguisher will be mounted with the location being readily accessible and marked according to OSHA regulations. Locations of the extinguishers will be no more than 75 feet apart depending on the type of extinguisher. Fire extinguishers must be of the approved type and serviced on an annual basis. Tags noting when the extinguisher was last serviced should never be removed and should always be legible. V. SUPERVISORS Supervisors must ensure that their personnel are properly instructed regarding potential fire hazards involved in their work and around their work areas, the proper precautions to minimize fires and the procedures in case of fires. If training is needed, the local fire department can offer courses and training materials on fire prevention and response, fire safety, fire extinguisher operation and self contained breathing apparatus. VI. FIRE FIGHTING EQUIPMENT INSTALLED

1) Fire Detectors 2) Sprinklers 3) Extinguishers 4) Alarms 5) Fire Doors

VII. FIRE EXITS Exit corridors must never be used for storage. The Life Safety Code, NFPA 101, requires that buildings that are designated for human occupancy must have continuous and unobstructed exits to permit prompt evacuation of the occupants and allow necessary access for responding emergency personnel. The intent of the code is to keep exits free from obstructions and clear of combustible materials. Attention to housekeeping is therefore very important. Any temporary storage of furniture, equipment, supplies, files or anything else is never permitted in exit ways. Combustibles, including recyclable waste paper, are not permitted in exit ways.


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Fire exits/doors are never to be locked from the inside. Please report any obstruction to egress routes to your immediate supervisor as soon as they are discovered VIII. FIRES/EMERGENCIES If a fire breaks out in the building, the company has designated certain employees who have been specifically trained and certified to extinguish fires. All employees are expected to be able to follow fire safety procedures, direct evacuations if necessary and to be knowledgeable and able to use a fire extinguisher. Each employee should familiarize themselves with the posted evacuation plans. In the event of a fire, the primary concern is saving lives. It is imperative that you exit using the nearest means of egress. It is every employees responsibility to know the locations of the first aid stations that have been placed throughout the facility. First aid stations and eyewash stations will be inspected monthly for proper supply and operation. All employees will be certified in first aid annually. Emergency numbers are posted on each telephone.


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CHAPTER 6 GASES

I. INT

Risk ManagementGeneral Industry

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