1.INTRODUCTION... ...8 A. Internet Access...9 B. Acknowledgements ...9 C. Cover Back ...9 D. Policy ...9 E. Our Mission...9 F. Our Commitment ...9 G. VPP Program...10 H. Purpose ...10 I. Point of Contact ...10
J. Contractual Construction Safety Statement ...10
K. Safety Qualification Requirements ...11
2. CONTRACTOR TRAINING REQUIREMENTS...11
A. Site Safety & Security Orientation (updated)...11
B. Verification of OSHA mandated training...11
C. Worker Safety and Health Program – 10 CFR 851 (new)...12
D. Training Badges...12
E. Occupational Safety & Health (OSHA) Training (updated) ...13
F. Certification of Training...14
3. REFERENCES (updated)...15
A. Federal Compliance Documents ...15
B. National Fire Protection Association Standards...15
C. Department of Energy Orders ...15
D. Definitions...16
4. FACILITIES ENGINEERING PROJECT COORDINATION...17
5. CONSTRUCTION SAFETY & HEALTH PROFESSIONAL (updated)...17
7. SAFETY PROGRAM ELEMENTS (updated) ... 18
A. Cover page ...18
B. Qualification list...19
C. Activity Hazard Analysis ...19
D. Medical Care Provider (new)...19
E. Flow-Down Clause...19
F. Weekly Safety Meetings ...19
G. Hazardous Materials...20
H. Pollution Prevention...20
I. Daily Hazard Analysis...20
J. Demolition Activities...20
8. SAFETY PROGRAM IMPLEMENTATION ... 21
A. Seller management leadership and employee participation in ES&H at KCP. ...21
B. Hazard identification and assessment...21
C. New means and methods...21
D. Hazard prevention and control at KCP...21
E. Safety information and employee training/qualification...22
F. Periodic evaluation of program effectiveness...22
9. SAFETY INSPECTIONS & MEETINGS... 22
A. Facilities Engineering Inspections of the Construction Sites...22
B. Inspections by NNSA/KCSO Personnel...22
C. Inspections by Environment, Safety, and Health (ES&H) ...22
D. Seller Inspections and Reviews...22
E. Monthly Superintendent Meetings...23
10. WARNING TICKETS & CITATIONS ... 23
A. Warning Tickets...23
B. Citations...23
C. Contract Remedies...24
D. Sellers Disciplinary Process ...24
11. REPORTING/POSTING REQUIREMENTS ...25
A. Unforeseen Hazard Posting ...25
B. Accidents/Injuries/First aid cases ...25
C. Property Damage (updated)...25
D. Tabulation of Work-Hours...25
E. Posting Requirements ...25
F. Posted Construction Areas...26
G. Emergency Evacuations, Reporting and Medical Care (updated)...26
H. Equipment Identification/Removal from the plant...26
12. PERMITS (updated) ...27
A. Types ...27
B. High Hazard Construction Safe Work Permits ...27
C. Utility Location & Excavation Permit...28
E. Life Safety Aisle/Exit Impairment Permits...28
F. Utility System Modification Permit ...29
G. Revocation of Permits ...29 13. ENVIRONMENTAL PROTECTION...29 A. Excavation Concerns...29 B. Hazardous Waste ...29 C. Equipment/Tools Decontamination ...29 D. Asbestos Abatement ...30 E. Decontamination...30
F. Discharge to Drain Systems...30
G. Storage of Hazardous Waste ...30
H. Disposal of Hazardous Waste ...30
I. Spills and Leaks...31
J. Environmental Control ...31
K. Dust Control...31
L. Visible Emissions...31
M. Prevention Guidelines ...31
N. Transport of Equipment...31
15. FIRE PROTECTION ... 32
A. Fire Protection Equipment ...32
B. Aisle Blockage ...32
C. Fire Rated Walls ...32
D. Internal Combustion and Propane-Powered Vehicles and Equipment...33
E. Flammable Liquid Storage and Use ...34
F. Hot Work (Welding, Cutting, Grinding, or Spark-Producing Activities) ...37
G. Portable Heaters...39
H. Housekeeping...40
I. Storage of Combustible Materials ...40
J. Smoking Policy ...40
16. INDUSTRIAL HYGIENE & HEALTH PHYSICS... 41
A. Hazardous Material Sampling ...41
B. Employee Protection Systems...41
C. Ventilation and Dust Control...41
D. Painting / Coating Application Guidelines ...42
E. Noise...43
F. Asbestos-Containing Material...43
G. Non-Ionizing and Ionizing Radiation...43
H. Hazard Communication...44
I. Confined Space Entry...44
J. Hazardous Material Labeling Requirements ...45
K. Lead...45
L. Beryllium Awareness ...46
M. Beryllium Training...46
N. Beryllium Tools ...47
O. Subcontractor Beryllium Workers...47
P. Beryllium Worker Blood Test...48
Q. Beryllium Air Monitoring...48
R. Moving Equipment Used to Process Beryllium ...49
17. MEDICAL SURVEILLANCE PROGRAM (new)... 50
A. Respirator Medical Monitoring Requirements ...50
E. Asbestos Medical Monitoring Requirements...50
18. SAFETY ...51
A. Personal Protective Equipment Requirements...51
B. Overhead Work Hazards (New) ...52
C. Securing the Work Zone...52
D. Safety Guardrails...53
E. Moving Load Limits on Elevated Floor Slabs ...53
F. Scaffold Tagging System...54
G. Scaffolds ...55
H. Ladders and Aerial Lifts...55
I. Powder-Actuated Tools ...56
J. Portable Air Compressors / Pressure Vessels (new)...56
K. Plant Compressed Air Systems (new)...56
L. Helicopter Lifts...56
M. Cranes ...56
N. Excavations ...57
O. Electrical Safety...58
P. In-Plant Vehicles (Powered Industrial Trucks and Carts)...60
Q. Customized/Modified Heavy Equipment ...60
R. Motor Vehicles and Mechanized Equipment...61
S. Steam Systems...61
19. DRILLING INTO CONCRETE OR ASPHALT (new) ...61
A. Penetrations Greater Than 4 Inches ...61
B. Penetrations Less Than 4 Inches...61
20. ROOF WORK...62
A. Roof Work Notification...62
B. Temperature Drop ...62
C. Icy Conditions ...62
D. Roof Damage...62
E. Weight Restrictions...62
F. Roof Crane Use...62
G. Material Storage ...63
H. Roof Drains...63
I. Vehicle Standards For Use On The Roof...63
21. SECURITY REQUIREMENTS ... 65
A. Security Badge Requirements (updated) ...65
B. Physical Security ...65
C. General Security Awareness...65
D. Badge Procedures...66
E. Building Access ...66
F. Identification of Controlled and Prohibited Articles...67
G. Protection of Unclassified Controlled Nuclear Information...67
H. Procedures for Reporting Safeguards and Security Concerns ...67
I. Identification of Classification Markings ...67
22. EQUIPMENT SUPPLIES AND DELIVERY... 68
A. MSB Deliveries (updated)...68 23. WEATHER RESTRICTIONS ... 69 A. Wind conditions: ...69 B. Lightning: ...69 C. Ice/snow:...69 D. Heat conditions:...69
Appendix A Construction Safety Plan Outline (updated) ... 70
Appendix B Weekly Construction Safety Checklist... 73
Appendix C Warning Ticket Example ... 76
Appendix D Citation Example ... 77
Appendix E DOE F 5484.3 ... 79
Appendix F Critical/Unusual Lift Plan... 84
Appendix G Safety Requirements for Contractor Lockout/Tagout... 86
Appendix H Permit for Energized Electrical Task (PEET)... 98
Appendix K Helpful Telephone Numbers (updated) ...112
Appendix M Construction Qualification Requirements (updated)...118
Appendix N Activity Hazard Analysis ...121
Appendix O Daily Hazard Analysis...123
Appendix P Safety Professional Responsibilities (updated)...124
Appendix Q Penetration Checklist (new)...127
Appendix R Utility Location & Excavation Permit (updated)...128
Appendix S Utilities Permit For Modification ...130
1.
INTRODUCTION
Safety is our priority. At the Kansas City Plant, our concern for safety begins before the start of your project. We launched a “Safety as a Lifestyle” campaign that encourages our associates to approach safety as a vital and ever-present part of their daily lives. We look to our construction contractors to strive for the same level of safety commitment.The Kansas City Plant is committed to working with you to ensure a safe and healthful workplace for both your employees and our associates. The Kansas City Plant has proudly achieved star status in the Department of Energy Voluntary Protection Program (VPP) and ISO 14001, the Environmental Management System Standard. With your help, we can remain one of the safest and most environmentally friendly facilities in the DOE community.
This handbook will assist you in producing a project-specific safety plan for construction contract work to be performed for The Kansas City Plant.
This document is not intended to cover all aspects of a safety program, but it is intended to provide guidelines to assist your company in developing a quality safety plan. Local
policies and practices can be added to these guidelines to provide a more practical vehicle for each contractor’s immediate needs.
All Sellers shall take reasonable precautions under this contract to assure the safety and health of KCP’s associates and assure the protection of plant operations from damage that might result from construction activities.
It is the Seller's continuing and absolute responsibility for all aspects of construction safety on their jobsite at the KCP. Any action or inaction by KCP’s or the NNSA or their
designated representative shall in no way alleviate Seller's responsibility or in any way create liability on the part of the Buyer or the NNSA.
Notice: This handbook provides requirements and illustrations in effect on the date of publication, February 2007. Requirements are subject to change without notice. If you currently have an active construction project, you will receive changes and updates as they become available.
A. Internet Access
If you are currently working at the Kansas City Plant and have computer access, this handbook is available on-line. Through “Portal” home page under “Safe and Secure,” click on “ES&H” then ”Contractor” to view the most up-to-date version of this handbook as well as other safety and environmental information. You can also access the
handbook outside of the plant at www.kcp.com. B. Acknowledgements
This book has been revised and edited with the assistance and input from the following KCP organizations: Environmental Safety & Health, Facilities Engineering, Fire
Protection Services, Legal Services, Graphic Arts and Communications. Additionally, the following contractors graciously provided their assistance: Facility Engineering Services and Superior Electrical Construction. We are constantly striving to improve the usefulness of this document to you, our customers. We welcome any comments or suggestions you may have for our next printing. We can be reached in the Safety and Health Department at (816) 997-5142.
C. Cover Back
Back Cover: FM&T’s Integrated Safety Management (ISM) logo: a common sense approach to doing work safely. Treat safety as an equal and essential part of the job, not as an add-on or afterthought. ISM’s approach tailors hazard control to the work being performed. This is the key element to writing a successful site-specific safety plan.
D. Policy
It is the policy at the Kansas City Plant (KCP) to assure that construction and construction-related contracts comply with site-specific, federal, state, and local requirements concerning safety, health, fire protection, and environmental protection standards.
E. Our Mission
We will achieve a world class level of safety performance for contractors working at Honeywell locations through increased safety awareness, communication of
expectations, and following work processes which reduce at-risk behaviors. F. Our Commitment
We recognize that outstanding safety performance is essential to the welfare of all associates, contractors and to business excellence. We will continue to improve our global competitiveness by making safety an integral part of all business activities.
G. VPP Program
The KCP has proudly achieved star status in the Voluntary Protection Program (VPP) which recognizes our employees and contractors for demonstrating the highest level of safety and health performance. Under this program you have the right to participate in safety and health issues at our facility, report or stop unsafe conditions, review accident reports and take an active role in improving our safety and health program. We
encourage you to attend the various construction safety meetings held throughout the year. Thanks again for making the KCP a national leader in safety and health.
H. Purpose
The following requirements shall be fulfilled by the contractor and each lower-tier subcontractor (for the remainder of this document referred to collectively as "Seller" when the requirements apply to either party).
I. Point of Contact
Our Buyer has designated the Project Engineer as the Seller's point of liaison for any Seller activity described in this document as requiring any joint approvals by
Environment, Safety, and Health (ES&H). J. Contractual Construction Safety Statement
In the event of an imminent danger violation (a condition or practice existing which could reasonably be expected to cause death, serious physical harm, or extensive environmental/property damage if it were not stopped), a Stop Work Order and Citation will be issued to the Seller.
The following individuals are authorized to issue a Stop Work Order: 1. Purchasing on the recommendation of Facilities Engineering; 2. NNSA Contracting Officer;
3. ES&H associates (Fire Prevention, Health & Safety or Environmental Protection). The Stop Work Order will be written by the Project Engineer. Verbal direction will be given to stop work when an imminent danger condition exists.
The Seller will be notified when to resume work after a Stop Work Order has been issued. The Seller shall make no claims for extensions of time or for compensation or damages by reason of or in connection with such work stoppage.
KCP employees may also intervene if they see a construction contractor performing an unsafe act.
K. Safety Qualification Requirements
The Kansas City Plant qualifies general contractors to assure that they meet established safety criteria prior to being allowed to work and they are committed to working safely while at the Kansas City Plant.
Qualification requirements are established in a two-step system. All general
contractors must meet the requirements of the first step (PART 1); Then complete part on on-site visit of your facility (PART 2).
Contractors who pass the qualification process will be added to the KCP’s list of qualified companies and will remain on the list until March 1 of the following year. If a general contractor is under contract, they will remain qualified for the duration of their contract.
The specifics of the two-step system are further defined in appendix M.
2. CONTRACTOR TRAINING
REQUIREMENTS
A. Site Safety & Security Orientation (updated)All personnel who will be working at the Kansas City Plant will be required to attend an orientation class. The class is held every Monday at 9:00 a.m. Have your employees arrive at the main entrance. (See map at back of book for plant location.)
Allow one and a half hours for the security badging and orientation class. If you are going to be on site for a short time, three days or less, we will come directly to your work area and present the orientation class.
Your project coordinator will arrange the orientation class. Any time you bring new subcontract employees on-site you must notify the Safety Department to schedule an orientation class. All new employees who will be on-site for one week or more must start on Monday. Note: the orientation class schedule is subject to change. All affected contractors will be notified on any schedule changes.
B. Verification of OSHA mandated training
All new construction employees and subcontractors whose companies have ten or more employees shall submit for verification certificates or training records indicating they have completed OSHA mandated training. Employees will not be allowed to attend orientation class without bringing their training records. See sections D and E below for details.
C. Worker Safety and Health Program – 10 CFR 851 (new)
February 2007 the new worker safety and health program will go into effect. This
regulation requires NNSA contractors and subcontractors to comply with all OSHA safety and health regulations. This handbook will assist you in meeting these requirements. The DOE/NNSA may audit the seller’s activities to ensure compliance with the regulation. 10 CFR 851 can easily be accessed on the internet.
D. Training Badges
A safety and security orientation badge will be issued to all crafts who complete the class. This card must be presented to the security guard when returning to gain access to the plant. This card is proof that your employees and subcontractors have completed the site safety and security orientation class. The new program started September 1, 2005. If you are bringing in a subcontractor, check to see if they have training badges prior to their first day of work.
Below is the procedure for forgotten or lost orientation badges. Forgot Badge
Your employee/sub contacts project superintendent and waits in guard shack. Superintendent calls extension 3181 and gives employee name.
Superintendent comes down to ES&H at OB48 ½ to pick up temporary badge. Superintendent delivers badge to employee waiting in guard shack.
Temporary badge will expire in 24 hours. Lost Badge
Your employee/sub contacts project superintendent and waits in guard shack. Superintendent calls extension 4040 and gives employee name.
Superintendent comes down to ES&H at OB48 ½ to pick up replacement badge. Superintendent delivers badge to employee waiting in guard shack.
Details
Third badge re-print due to loss results in warning ticket to general contractor. During emergency repair situations, employees will be allowed to work if they forget their badge.
No temporary or badge replacements will be issued on weekends or holidays or outside normal business hours.
E. Occupational Safety & Health (OSHA) Training (updated)
The Seller (including lower tier subcontract employees) engaged in construction, abatement or remediation activities that require OSHA or other applicable mandated training and/or certification shall maintain documentation onsite, verifying completion of required training.
All construction contractors coming on site must show proof of completing OSHA
mandated training prior to starting work at the Kansas City Plant. This requirement is an expectation of The National Nuclear Security Administration (NNSA).
Everyone is required to have the two courses listed below:
Hazard Communications Training – 29 CFR 1910.1200, and 29 CFR 1926.59 (h) (2) All employees must show proof of being trained in the Hazard Communication Standard.
Ladder & Stairway Safety – 29 CFR 1926.1060 Training is required for each employee using ladders and stairways.
Depending on your job tasks, your employees may need the following:
Please Note: This is only a short list of potentially required training bring any additional OSHA or EPA mandated training you may have.
Fire Extinguisher Training – NFPA 51B standard for fire prevention during welding, cutting and other hot work Any employee designated for fire watch duty for hot work i.e. welding, cutting or spark producing activities must have this training. Training shall include proper selection, use and application of
extinguisher agents, characteristics and classification of fires.
Confined Space - 1926.21 (b) (6) and 29 CFR 1910.146 any employee who will be entering a confined space shall be trained.
Lockout/Tagout - 29 CFR 1910.147 (c) Any employee who will be working on potentially energized, mechanical, temperature extreme or pressure systems must be trained in Lockout/Tagout methods.
Powered Industrial Trucks (fork truck operator training) - 1910.178 (I) Any
employee who will be operating a forklift must have an operators permit showing the employee has completed the training required by this standard.
Powder-Actuated Tools (ram set) – 29 CFR 1926.302 (e) If you will be using a ram-set you must have you operators training card.
HAZWOPER – 1926.65 and 29 CFR 1910.120 Hazardous Waste And
Emergency Response Standard. The 40-hour training course and certification is required of employees who will be performing hazards waste clean up or
working in regulated areas.
Asbestos Abatement– 29 CFR 1926.59 Any employee performing asbestos abatement must show proof of completing an approved asbestos abatement course.
Lead Abatement – 29 CFR 1926.62 and 29 CFR 1910.1025 and Missouri
regulation 10 CSR 30-70.150 - Any worker performing lead abatement must show proof of completing a EPA approved Missouri Lead Abatement Worker certificate.
F. Certification of Training
The written certification record shall contain the name of the employee trained, the date(s) of training, and the signature of the person who conducted the training or the signature of the employer. If the employer relies on training conducted by another employer. The certification record shall indicate the date the employer determined the prior training was adequate rather than the date of actual training.
We look forward to having you as a part of our construction team here at the Kansas City plant. With your help, we can remain one of the safest and most environmentally friendly facilities in the DOE community.
3. REFERENCES
(updated)
These are a few selected references that may help you with preparing your site-specific safety plan.A. Federal Compliance Documents
Safety & Health record keeping required 300 & 300A logs (See www.osha.gov) Safety and Health Regulations for Construction, Code of Federal Regulations (CFR), Title 29, Part 1926
Chronic Beryllium Disease Prevention Program, 10 CFR Part 850 Occupational Safety and Health Standards, CFR, Title 29, Part 1910
Environmental Protection Agency Regulations, CFR, Title 40, Part 61, Subpart M, National Emission Standard for Asbestos
Environmental Protection Agency Regulations, CFR, Title 40, Part 262, Subpart C, Pre-transport Requirements for Hazardous Wastes
Department of Transportation Regulations (Parts 100-177) Worker Safety and Health Program – 10 CFR 851
B. National Fire Protection Association Standards
NFPA 70-E Standard for Electrical Safety In The Workplace 2004 edition NFPA 30 Flammable and Combustible Liquids Code
NFPA 33 Standard for Spray Application Using Flammable and Combustible Materials
NFPA 241 Safeguarding Construction, Alteration and Demolition Operations NFPA 70 National Electric Code
NFPA 51B Standard for Fire Prevention During Welding, Cutting and other hot work 2003 edition
C. Department of Energy Orders
To review the current Department of Energy and NNSA requirements, see
D. Definitions
Basic Contract definitions are included in the General Conditions and in the Terms and Conditions of Purchase. In addition to these definitions, the following definitions apply to this Construction Safety Handbook:
Area Owner KCP representative with oversight responsibilities for the space in which work is occurring.
Buyer NNSA’s Kansas City Plant operated by Honeywell Federal Manufacturing & Technologies LLC.
Seller Corporation, partnership, joint venture, or individual which enters into a purchase order with Honeywell FM&T.
Safety Professional
Individual who has academic credentials or work experience in a
relevant discipline, such as environmental protection, industrial hygiene, industrial safety or health physics and who has practical knowledge of the work activities.
Competent
Person One who is capable of identifying existing and predictable hazards in thesurroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.
Activity Hazard Analysis
A document that includes identification of principal work steps, site hazard and controls, task hazards and controls and necessary permits and training.
Daily Hazard A documented daily review of work tasks by a competent person with Analysis crafts, identifying task-related hazards, controls, permitting
requirements, and validation of training associated with the work to be performed. Crafts will sign document and post on job site daily.
DOE United States Department of Energy. "DOE/AL" refers to the Department of Energy, Albuquerque Operations.
ES&H Buyer's Environment, Safety, and Health Division.
FES Facility Engineering Services, LLC, a subsidiary of Burns and McDonnell Engineering.
FM&T The Kansas City Plant and Kirtland Operations, collectively managed by Honeywell.
ISM Integrated Safety Management. The 5 core functions of ISM are: 1) Define scope of work. 2) Analyze the hazards 3) Develop & implement
KCP The Federal Complex at 2000 E. Bannister, Kansas City, Missouri. KCP facilities are operated by the Buyer pursuant to a contract with the
Department of Energy.
LOTO Lockout/Tagout Program, used to minimize risk of interaction between workers and a dangerous energy source. The program is located in appendix G.
NFPA National Fire Protection Association.
NNSA National Nuclear Security Administration, an agency of the Department of Energy.
HHCSWP High Hazard Construction Safe Work Permit (form 2953). KCSO Kansas City Site Operations.
Project Engineer
The Project Engineer is the agent of the Buyer to the extent expressly authorized by the purchase order documents and will, in general,
inspect, observe, and report concerning the work. The Project Engineer is authorized to stop the work, whenever necessary in their opinion, to ensure the safe and proper execution of the work. The Project Engineer can be either a contract engineer or Honeywell associate.
Purchase Order
Same as the term "contract" or "contract documents" and refers to the purchase order issued between Seller and Buyer.
RCRA Resource Conservation and Recovery Act.
4. FACILITIES ENGINEERING PROJECT
COORDINATION
A checklist was developed to ensure no safety, health and environmental aspects of construction planning will be overlooked. An example of this checklist is in Appendix L. This checklist will be used by the Facilities Engineers and Planners.
5. CONSTRUCTION SAFETY & HEALTH
PROFESSIONAL
(updated
)
Depending on project size or scope The Kansas City Plant may require your project to be staffed by a safety & health professional to provide direct oversight and maintain your safety & health program while working at the Kansas City Plant. The safety professional may also act as the on site construction safety competent person. Qualifications and expected duties of the safety & health professional are outlined in Appendix P.
6. ON SITE CONSTRUCTION SAFETY COMPETENT
PERSON
(new
)
All construction projects are required to have a construction safety competent person on site during periods of active construction. This individual’s responsibilities include:
Lead the Daily Hazard Analysis (DHA) meeting at the beginning of the shift Identify and correct unsafe conditions
Stop work if hazardous conditions are encountered
Revise the Activity Hazard Analyses and/or Daily Hazard Analysis where need Complete the weekly construction safety checklist
Ensure all employees and subcontractors have completed the KCP ES&H site safety orientation prior to starting work
Ensure all required ES&H permits are current and posted for the project
Review and have a working knowledge of the KCP Construction Safety Handbook This individual will be identified in the seller’s project safety plan. The individual must complete the OSHA 10 hour construction safety training program and hold the 10-hour construction safety card at a minimum.
7. SAFETY PROGRAM ELEMENTS
(updated)
The Seller has the responsibility to follow a general health & safety program, develop and implement project specific health & safety plans that address unique hazards and
conditions related to their project. The Seller is the entity having overall responsibility and control of the project. The Seller’s health & safety program must demonstrate the
elements identified below for maintaining safe working conditions and assuring safe work practices for its employees. The Seller’s lower tier subcontractors shall operate within the purview of the Seller’s Safety Program and Project Specific Safety Plan.
This must be a detailed plan covering the actual project you and your subcontractors will be working on. Look at all phases of the job: demolition; remodeling and equipment
installation. After reviewing the project drawings and specifications, address what you will be doing and how your workers will be protected.
No work can begin on the construction project until the safety plan is written and accepted by KCP (See appendix A for elements to include). Your written safety plan is a
construction submittal and must be submitted as specified in construction specification section division 1 general requirements, section # 01330, title submittal procedures. All of your personnel and lower tier subcontractor personnel shall be briefed on the safety plan and know where a copy is maintained. The plan must include the following:
B. Qualification list
The Seller shall provide the name and qualifications (i.e., training, past experience, education) of the jobsite management and the competent individual assigned responsibility for administration of the safety and health program. A method of contacting the representatives on-site shall be included.
C. Activity Hazard Analysis
This is the heart of your site-specific safety plan. This consists of the identification of site hazards and controls, principal work steps, associated task hazards and controls, necessary permits, and worker training. In other words, Integrated Safety Management (ISM). ISM is a common sense approach to doing work safely. Treat safety as an equal and essential part of the job, not as an add-on or after thought. All Seller and lower tier subcontract personnel shall be briefed on the Seller’s project specific safety plan and Activity Hazard Analysis prior to performing work. Copies of the AHA and Project Specific Safety Plan will be maintained and available for review by all Seller and lower tier sub-personnel. A copy of the approved AHA shall be posted at the project site. The Seller shall update the Activity Hazard Analysis to address specific items of work when new hazards are identified or when phasing of work benefits from later receipt of supplemental work specific information. See appendices N and O. D. Medical Care Provider (new)
Each seller shall identify their selected health care provider in the site specific safety plan. The medical care provider will be responsible for evaluation and medical care of the seller’s employees who will be working at the KCP. The seller shall also provide pertinent information to their selected health care provider of hazardous materials their employees are exposed to. This will ensure the sellers employees are covered in medical monitoring programs. These include hazards requiring medical monitoring under OSHA, for example, asbestos, lead, noise, or beryllium. (see section 16 for more details on medical surveillance requirements)
E. Flow-Down Clause
All requirements of the safety program shall be included in the purchase orders as flow-down clauses. The Seller’s lower-tier subcontractors must comply with the Seller’s safety program and project specific safety plan.
F. Weekly Safety Meetings
The Seller’s project foreman, safety professional and/or competent person shall conduct weekly safety meetings on-site, and maintain written attendance sheets
including safety topics discussed. Foreman shall provide copies of meeting attendance and safety topic sheet to ES&H when requested.
G. Hazardous Materials
Environmental restoration projects or other projects involving exposure to hazardous materials shall include a site-specific determination of the levels of personnel
protection, decontamination area(s), emergency notification procedures, and method of keeping unauthorized personnel off the site. If you will be involved in remediation sites or deal with hazardous materials, you may be required to submit a safety plan which addresses the impact of 29 CFR 1910.120.
H. Pollution Prevention
Include the following statement in your safety plan, "Consistent with the national policy, pollution shall be prevented or reduced at the source wherever feasible." Describe the activities you will undertake to meet this policy. This applies to all forms of pollution, i.e., air emissions, water discharges, and solid waste.
I. Daily Hazard Analysis
Seller and lower-tier subcontract personnel shall be briefed daily on assigned work tasks, associated hazards and their controls prior to commencing work (reference appendix O). This briefing shall be documented and available on premises for the duration of the project. Those workers failing to utilize appropriate protective measures are subject to the warning ticket / citation process.
J. Demolition Activities
If the project requires the Seller to perform demolition activities, the Seller shall create a section in the project specific safety plan that addresses demolition activities. The demolition plan shall state the hazards expected to be encountered during the course of normal demolition activities. Include what will be done to minimize the hazards identified and protect the employee during demolition. Items to consider include lead paint, electrical systems, plumbing, duct removal, steam systems and other energized systems etc.
EXAMPLE: This project includes the demolition of electrical circuits. Hazards normally encountered in electrical demolition include exposure to electrical energy. To assure worker safety, only qualified electricians trained to recognize and
eliminate electrical hazards will be utilized to perform electrical demolition activities. If the demolition plan utilizes laborers to perform electrical demolition, a plan to assure the laborers safety shall be provided. – example: use of lo/to, marking the lines to distinguish between energized and de-energized lines. Lines identified shall be physically disconnected at both ends.
8. SAFETY PROGRAM
IMPLEMENTATION
To ensure your written safety plan is followed by both your employees and sub-tier employees, the following must be included in the implementation of your written safety plan.A. Seller management leadership and employee participation in ES&H at KCP.
Seller’s program shall demonstrate that managers, supervisors, and employees are provided with the authority to access relevant information, training and resources to carry out their Environmental, Safety & Health responsibilities.
For projects that do not require a full-time Safety Professional on-site, the Seller shall designate the on site competent person(s) who holds at a minimum the OSHA 10 hour construction safety card to assume the role and responsibility of the safety
professional. The Seller’s safety professional shall be responsible for reviewing and monitoring all potentially hazardous operations.
B. Hazard identification and assessment
Seller’s program shall document that frequent and regular inspections of the workplace, materials, and equipment are made by competent persons designated by the employer. Seller shall document the assessment of project hazards and identify hazard controls for hazardous work elements prior to work start-up (Activity Hazard Analysis).
Seller shall evaluate and document daily work hazards, reviewing with employees prior to beginning work each day (Daily Hazard Analysis).
C. New means and methods
We are always open to new means and methods. If you have knowledge of a safer or new system for performing the job, let us know. We understand that tools, equipment and techniques continue to improve. If you have a process that is not covered in this handbook, let us know and we will evaluate your plan.
D. Hazard prevention and control at KCP
Document hazard controls for work elements (tasks) using an Activity Hazard Analysis form (Appendix P) for work elements prior to work start-up. A project-specific Activity Hazard Analysis (AHA) must be written and accepted by the Buyer prior to work being performed. The AHA must include the following:
1. Sequential listing of the work elements (job tasks) within the project. 2. Potential hazards associated with each work element (job task).
3. Hazard controls for each hazard identified for work elements (job tasks). Document daily work hazards using a Daily Hazard Analysis form (Appendix O or similar) and review with employees prior to beginning work each day.
E. Safety information and employee training/qualification
Review ES&H information with workers and subcontractors as required. Workers shall be trained to minimum OSHA requirements.
Ensure each employee is adequately trained to perform assigned work.
Seller shall maintain a listing of training and qualification records of employees and lower tier subs at the KCP.
F. Periodic evaluation of program effectiveness
Perform periodic evaluations of your construction safety program to ensure it is effective and appropriate for workplace conditions.
9. SAFETY INSPECTIONS &
MEETINGS
A. Facilities Engineering Inspections of the Construction SitesThe construction site will be inspected on a routine basis. Warning tickets and citations will be issued through ES&H if health or safety violations are observed.
B. Inspections by NNSA/KCSO Personnel
The construction site may be inspected by a NNSA official at their discretion. NNSA/KCSO officials may also inspect projects on a routine basis.
C. Inspections by Environment, Safety, and Health (ES&H)
All construction sites are subject to routine inspection by ES&H. Warning tickets and citations will be issued if violations are observed. All ES&H violations will be routed through the Construction Manager/Title III Engineer for corrective action by the Seller. D. Seller Inspections and Reviews
Seller’s safety professional and or competent person shall make formal weekly
inspections of all Seller construction sites and activities. A construction safety checklist self-inspection sheet is included in this handbook (See appendix B). All construction contractors shall use this list to review their project sites. KCP’s ES&H will be auditing your construction sites to this list. Other daily or routine inspections shall be
documented as required by OSHA Standards.
1. The Construction Manager/Title III Engineer shall be made aware of such inspections and be invited to participate.
2. The Seller shall perform all corrective actions on all identified items in a timely manner.
3. Monthly, the inspection/audit data from the construction safety checklist shall be provided to the KCP Construction Safety Engineer.
E. Monthly Superintendent Meetings
Monthly KCP’s Purchasing Department schedules safety meetings with all construction contractors on-site at that time. All on-site management or lead persons are required to attend. Your company will be required to present a safety topic to the group during the superintendent safety meeting. If your company has had an accident or injury during the period between meetings, you will be required to make a short presentation on the accident, lessons learned and corrective actions taken. We encourage you to take an active role in these meetings and share the information gained with coworkers.
10. WARNING TICKETS &
CITATIONS
A. Warning Tickets1. All minor violations will be documented by the Project Engineer or Safety Engineer through the use of a warning ticket. These shall be used to determine repeat violations by the Seller and/or lower-tier Seller. (See Appendix C)
(Non-serious violations that have a relationship to safety and health are those that probably would not cause death or serious physical harm.)
REQUIREMENT: Three warnings in a 30-day time period for the same concern shall result in the issuance of a citation.
2. Non-serious violations noted by KCP’s ES&H personnel or NNSA personnel may result in the issuance of a warning ticket to the Seller.
3. You must correct the non-serious violation within one day. The Seller shall contact the Safety Engineer for concurrence when action is completed.
B. Citations
Violations of OSHA 1926, Standards for the Construction Industry, any applicable parts of the OSHA 1910, General Industry Standard, or this handbook will be documented on the KCP’s Occupational Safety and Health Citation form. (See Appendix D.) Citations will be issued when one of the following occurs:
1. A violation which could reasonably be expected to cause death, serious physical harm, or extensive property/environmental damage if it is not stopped
immediately (citation);
2. A violation that the Seller intentionally and knowingly commits or is aware that a hazardous condition existed and made no reasonable effort to eliminate it
(willful);
3. A violation of any standard, regulation, rule, or order where, upon re-inspection, a substantially similar violation is found (repeated);
4. A violation where there is substantial probability that death or serious physical harm could result and that the employer knew or should have known of the
5. Violations that could result in a citation noted by ES&H personnel will result in a citation.
6. NNSA may issue citations through KCP at any time. C. Contract Remedies
Buyer reserves the right to take any contract actions necessary for violation of the safety requirements, including termination of the contract for default.
D. Sellers Disciplinary Process
All general contractors shall have a written disciplinary process for both their
employees and subcontractors who fail to utilize appropriate protective measures on the job site.
E. Employee Expulsion Policy
Any contract employee who is removed from the Kansas City Plant for failure to follow established ES&H or Security requirements may not be allowed to return to the KCP as a contractor or under employment for another seller. Additionally, any contract
employee who does not meet performance expectations may not be allowed to return to the KCP. Each individual case will be reviewed. Names of individuals that have been removed will be tracked by the Security Department to deny entry to the facility. This rule applies to the Seller’s employee who is removed from the plant by KCP’s or the sellers’ management.
11. REPORTING/POSTING
REQUIREMENTS
A. Unforeseen Hazard PostingWorkers must be instructed to report to the project supervisor hazards not previously identified or evaluated. If immediate corrective action is not possible or the hazard falls outside of project scope, the project supervisor must immediately notify affected
workers, post appropriate warning signs, implement needed interim control measures, and notify the project engineer of the action taken. The contractor must stop work in the affected area until appropriate protective measures are established. Unforeseen
hazard signs are available from KCP ES&H if needed. B. Accidents/Injuries/First aid cases
All construction and non-construction injuries which take place at the Kansas City Plant shall be reported to the Safety Department immediately. KCP associates will assist and provide you with the forms identified below.
DOE Form 5484.3, "Report of Occupational Injury/Illness," to be completed for each reportable occupational injury or illness, as defined by OSHA, involving any
employees (See Appendix E). C. Property Damage (updated)
All fires, property damage, accidents, or losses to government property must be reported to the Project Engineer.
D. Tabulation of Work-Hours
All construction work-hours must be reported to the buyer monthly. Work-hours must include both the general contractor and all subcontractors who worked on the construction project. List work-hours and company names of each subcontractors. This report shall be submitted to the KCP purchasing department monthly and will be due on the first day of the next month. This form is available from the buyer. E. Posting Requirements
The Occupational Safety and Health Protection Poster (F 5483.1 [12-93]) shall be posted on all projects or work centers. The Seller shall assure that their personnel are aware of their health and safety rights.
F. Posted Construction Areas
All construction areas shall be posted appropriately by the construction general contractor. All signs are available from ES&H.
The Seller shall:
Post “Remain Clear Of Construction Work” and project information sign as well as any required permits at the main point of entry into each construction area. Post “Construction Area Hard Hat & Safety Glasses Required” within the construction work area.
Provide and place warning signs and barricades for the protection of
non-construction personnel. Construction area boundaries are to be identified by rope, barrier tape, fencing, or other means. The area must be of sufficient size to contain the hazard. Take into account the height of what is being worked on. Adjust the size of the work area boundaries as necessary during the project.
When performing work outside of the posted construction area (installing equipment on the roof as part of a project below) install barricade tape around the work area and attach a “Notice” tag to the barrier tape with project number and contact person with telephone or pager number.
G. Emergency Evacuations, Reporting and Medical Care (updated)
1. When a siren/warbling tone is heard over the emergency notification system, it indicates a plant emergency. All personnel shall leave the work area and wait for further instructions.
2. If an emergency situation exists such as fire, injury, environmental damage, or explosion, call 3600 for assistance. The individual reporting the incident shall state his or her name, location, type of emergency, and location of the
emergency.
3. It is the responsibility of the Seller to direct the medical care of their employees through their identified medical provider. The KCP Medical Care Services will provide only emergency and stabilization care.
4. Contractor personnel shall participate in an annual emergency evacuation or sheltering drill if they are on-site during the time and day of the drill. The drill will last approximately 30 minutes, not to exceed one hour. The Seller will not be reimbursed for participating in the drill.
H. Equipment Identification/Removal from the plant
12. PERMITS
(updated)
A. TypesVarious work permits and forms are required for construction and construction-related service activities such as:
Penetration Checklist
Utility Location and Excavation Permit Hot Work Permit
Life Safety Aisle/Exit Impairment Permit Confined Space Entry Permit
High Hazard Construction Safe Work Permit Permit for Energized Electrical Safety (PEET) Drain Connection / New Discharge Approved Form Fire Protection System Impairment
High Voltage Pre-Job Safety Checklist / Electrical Shutdown Utilities Permit for Modification
The Seller shall initiate all permits required to perform work at the Kansas City Plant and identify permitting requirements in the Project Specific Safety Plan/Activity Hazard Analysis (AHA) and Daily Hazard Analysis (DHA). The Seller shall complete required permits and obtain all signatures prior to proceeding with construction work. All permits shall be up to date and posted at the jobsite.
Hot Work Permits are issued by the KCP Fire Department. High Hazard Construction Safe Work Permits, Aisle Impairment Permits, and Utility Location & Excavation Permits are issued by Construction Management Associates. Many of these permits require advanced notice and coordination prior to work.
B. High Hazard Construction Safe Work Permits
High Hazard Construction Safe Work Permits are issued for non-routine high hazard operations such as but not limited to:
Scaffold work (any height) Steel Erection
Use of Cranes Helicopter Lifts Shoring
Critical / Unusual lifts
Concrete Masonry Wall Installation (> 8ft) High Voltage Work (Over 600V)
Removal of roofing materials and /or the removal/installation of items that penetrate the KCP roof.
Permits may be issued on a daily, weekly, or monthly basis. Completion of this form requires participation of contractors with ES&H, Project Engineer and area owner.
C. Utility Location & Excavation Permit
The Utility Location & Excavation permit shall be completed any time construction activity disturbs soil/sub grade, including penetrations through
slabs/floors/concrete/asphalt where the soil/sub grade will be disturbed.
Examples include internal or external excavation, trenching, soil borings, ground rod installations, or any other construction activity that has the potential to disturb a buried or encased utility in the soil.
Requesting a permit: Minimum 3-day advanced notice is required to adequately research and identify hazards that may exist at the excavation site.
These permits are generally issued on a daily or weekly basis depending on the operation. Permits may be issued for any period that is decided appropriate by the Project Engineer. Excavations should be reviewed prior to entry and the permits reviewed weekly as a minimum. Advanced notification is required to allow Buyer to perform a basic review of potential utilities in the area. Seller is responsible for
performing work in a manner that recognizes utilities may exist that are not identified by the Buyer’s utility locating equipment (See Appendix R).
Note: For areas outside the perimeter security fence Missouri One Call shall be contacted for utility locations (1-800-DIG RITE)
D. Penetration Checklist (new)
The penetration checklist replaces the class 2 penetration permit. The new checklist allows the contractor to locate utilities and re-bar themselves in concrete 4 inches or less in depth. The checklist shall be completed prior to any saw cutting, jack
hammering, drilling or penetration of asphalt, concrete ceilings, floors, columns, beams, roof ribs, concrete & metal roofs, footings, foundations, exterior slab on grade (concrete & asphalt) or suspended slabs (ramps, etc.) (See section 19 and Appendix Q.)
Exemption - Work under construction the Seller has installed as a part of the same project does not require a penetration permit.
E. Life Safety Aisle/Exit Impairment Permits
Life Safety Aisle/Exit Impairment Permits are issued for tasks that will require the aisle to be partially or totally blocked for a period of time. If an aisle must have on-going work, then a permit will be issued to identify the work and materials that will be within the life safety lines. Basically no more than one half of the aisle (minimum of 36”) may be blocked for a partial and the partial impairment must last two hours to require permitting. Total blockages require a 24-hour notice, considerable coordination and are generally permitted only on off-shift to keep the risk levels lower. Remember, if you block less than half the aisle for less than 2 hours, you do not need a permit.
F. Utility System Modification Permit
Utility system modification permit is required for all utility modifications, including those that install or remove equipment. The Seller/CM/Planner shall file a permit with the designated Utility Engineer prior to construction. The permit shall identify the system, location of work, type of work and estimated duration of the work. The Utility Engineer shall review and return the request for approval within 3 working days. The permit shall reside with the seller until the work is completed and post-installation testing is
performed. The Utility Engineer has the option to witness post-installation testing with 24-hour advance notice (See appendix S).
G. Revocation of Permits
Permits may be revoked for noncompliance violations. Upon revocation of the permit, the Seller shall submit in writing to the Project Engineer the corrective action that will be taken and action taken to prevent recurrence. If corrective action is acceptable,
another permit will be issued. Revocation of a permit will result in the issuance of a citation.
13. ENVIRONMENTAL
PROTECTION
The Kansas City Plant has achieved ISO 14001 certification, The Environmental Management System Standard. With your help, we can maintain our ISO status and be one of the most environmentally friendly facilities in the DOE community.
A. Excavation Concerns
Due to possible soil contamination, excavation work shall be initiated only after a Utility Location & Excavation Permit is issued. Excavated soils and wastewater policies shall be complied with.
B. Hazardous Waste
The disposition of all wastes must be addressed in the project specifications. For situations that are not addressed in the specifications, the Project Engineer shall coordinate with KCP’s Waste Management Department to resolve the discrepancy. C. Equipment/Tools Decontamination
Some demolition, equipment relocation and excavation projects have the potential to contaminate work tools and machinery. Contractors working in areas where
contamination is known to be present must include in their safety plan a
decontamination plan of equipment, including fork-trucks, skid steers, hand tools, etc. prior to removing them from the NNSA complex. Consider the use of cheap,
expendable tools as an option to cleaning. Some of the common contaminants include PCB oils and solvents. Should your project include this type of work, disposal and cleaning will be coordinated with KCP’s Waste Management Department.
D. Asbestos Abatement
If you suspect asbestos on your work site, stop work and contact the Project Engineer immediately. No asbestos removal or abatement work shall be performed by your employees. Should you find any asbestos pipe insulation on the floor, contact the SPIL hotline at extension 7745 to coordinate clean-up.
E. Decontamination
Water, steam, or other materials used to clean areas or equipment that may be contaminated with toxic or hazardous substances shall be contained. Disposal of all materials used shall be addressed in the project specifications or the buyer’s safety plan.
F. Discharge to Drain Systems
No construction materials, wastes, spills, or leaks, including oil, cleaning solvents, acids, caustics, coolants, concrete, mortar, gravel, sand, or fuel oil, shall be discharged to any storm sewer drain. No material shall be discharged to any sanitary or industrial sewer unless directed by the project specifications. Where discharge is anticipated as a part of a process, contractor shall provide containment systems to protect drains. Only rain event run-off may be discharged to storm sewers. Repeated or willful noncompliance to this requirement shall be sufficient reason for termination. G. Storage of Hazardous Waste
All storage of hazardous wastes (such as chemicals, toxic metals, asbestos) shall be in accordance with the requirements of the project specifications. Contractor shall
coordinate with project engineer and ES&H regarding storage of hazardous wastes not defined in the project specifications.
H. Disposal of Hazardous Waste
Hazardous waste containers are ordered for waste from each jobsite individually. Containers with the labels shown below have STRICT RULES for use and return. Your employees and subcontractors who work on a project where hazardous waste
containers are used must be aware of the following:
Containers labeled or stenciled can only contain that type of waste.
Do NOT move containers to another job, use anyone else’s containers, or abandon them when the job is over.
All containers must be covered and barrel rings secured when not in use. Fill out the end fill date when the container use is complete.
I. Spills and Leaks
Spills or leaks of any construction materials including oil, fuel, solvents, paint, coolants, acids, caustics, equipment leaks, overflows, toxic solids, asbestos or any other
construction materials, must be reported immediately to Waste Management through the SPIL Hotline, extension 7745, and the Project Engineer.
SPIL HOTLINE 7745 (SPIL)
SPILL: Any spilling, leaking, pumping, pouring, emitting, emptying, discharging, escaping, leaching, dumping, or disposing of a chemical into the environment. J. Environmental Control
Spills or leaks caused by faulty equipment or gross negligence of the Seller shall be determined by ES&H and the Project Engineer. This can be sufficient reason for job termination. To the extent possible, equipment leaks are not allowed. If a discernible equipment leak is identified, the project engineer may advise ES&H and identify
mitigating actions to control the leak up to and including removal of the equipment from the site. Equipment found by the Project Engineer to be in need of repair to prevent spills shall be taken out of service and repaired at no added cost to Buyer.
K. Dust Control
Dust generated by construction operations shall be controlled by water or other means acceptable to the Project Engineer, Buyer or ES&H.
L. Visible Emissions
Visible emissions, with the exception of water vapor from equipment vehicles, should be avoided.
M. Prevention Guidelines
Prevent pollution at the source and use less toxic materials wherever feasible. This applies to air emissions, water discharges, and solid waste generated.
N. Transport of Equipment
Prior to transporting operational equipment, drain, plug, and tag it with the appropriate label or tag.
14. LIFE SAFETY ON CONSTRUCTION
SITES
Every construction site shall have at least two exits. If two exit routes are not available, contact the KCP Fire Department for job site review. These exits and access routes to them shall be adequately lighted, including emergency lighting, and be adequately marked.The location of exits, number of exits, provision for normal and emergency lighting, and marking of exits shall be reviewed by a fire protection engineer at the beginning of
construction and whenever the course of construction requires a change to the site layout. Changes can occur because of security, safety, or construction progress. The installation of dust curtains and partitions can adversely affect life safety. Any door designated as an exit shall not be locked at any time. Fire Protection systems shall be maintained in service as approved by the fire protection engineer. This often involves temporary wiring until permanent circuits are installed. Requests for review should be made through the construction manager or planner.
15. FIRE
PROTECTION
A. Fire Protection EquipmentFire alarm panels, fire hose reels, fire extinguishers, sprinklers, alarm systems, or other fire protection equipment shall not be blocked, removed, or disconnected without the approval of the KCP Fire Protection Department.
At the KCP, fixed fire protection systems, to include fire sprinkler systems, alarm
systems, smoke and heat ventilation systems, fire doors, fire dampers, Halon systems, carbon dioxide systems, dry chemical systems, wet chemical systems, fire pumps, and water supply valves shall be shut down or placed in service by Fire Protection
Department associates only. Requests for the Fire Protection Impairment (E-2742) shall be made through the Project Engineer 24 hours prior to the planned shutdown or impairment.
B. Aisle Blockage
All egress aisles, fire lanes, emergency exit doors, etc., shall remain clear and functional for emergency use.
If activities necessitate blocking egress aisles, fire lanes, fire exits, and doorways, a Life Safety Aisle/Exit Impairment Permit (E-2812) request must be submitted to the project engineer a minimum of three days in advance for Fire Protection Department review and approval. A partial obstruction for less than two hours does not require the permit. A complete aisle blockage is generally not permitted during regular occupied hours.
C. Fire Rated Walls
Activities that impair fire rated walls shall be coordinated with sprinkler work so that both are not simultaneously out of service. Requests for impairing fire walls shall be made through the project engineer at least 24 hours prior to the planned impairment.
D. Internal Combustion and Propane-Powered Vehicles and Equipment
Propane-powered vehicles and propane-powered equipment shall comply with NFPA 58, NFPA 505, and be approved by the Project Engineer and Fire Protection
Engineering prior to using on-site.
1. Gasoline and diesel fueled vehicles and equipment shall not be permitted in or on buildings, except where permitted by the Project Engineer, Fire Protection and ES&H. When a diesel or LP powered industrial tool is needed, the following requirements shall apply:
a) All diesel-powered equipment operated inside the facility must be equipped with a properly operating scrubber/purification system or be directly
connected to an exhaust extraction system.
b) All diesel-powered equipment should be removed from the building when not in use. If the equipment must remain in the facility, contact the Fire
Department for approval.
c) Routing of the exhaust must be reviewed and accepted by the Project Engineer. If an exhaust system must be installed, the installation and removal of the system is the responsibility of the Seller. Existing systems may be used with acceptance of the Project Engineer.
d) Refueling activities shall be approved by the KCP Fire Protection
Department. Any equipment to be refueled on the roof must be done with the Fire Department present.
e) During equipment operation, the work area shall be monitored for carbon monoxide, explosive vapors, and oxygen levels as a minimum. Any elevated levels will require the equipment to be shut down and the area ventilated before work can resume.
2. Gasoline and diesel powered vehicles and other equipment not in use shall not be left within the buildings.
3. Liquefied petroleum gas shall not be stored within any building or on any roof at the Kansas City Plant.
4. Gasoline and diesel engines shall be refueled outside of buildings unless otherwise specifically permitted in writing by the KCP Fire Department. LP gas containers shall be changed outside of the building when possible.
E. Flammable Liquid Storage and Use
1. Storage of flammable liquids inside the buildings of the KCP must comply with NFPA 30 and the requirements listed below. Flammable Liquid Storage Cabinet Location Guidelines, Flammable liquid cabinet placement shall reflect the following:
a) Boundary areas a minimum of 5 feet from the edge of each side and 3 feet from top of the opening of the cabinet and free of ordinary combustibles. b) NOTE: Walls may reduce the dimensions on the sides and top of the cabinet
by altering the flammable liquid vapor path to travel. Vapor travel distance to ignition source shall not be less than noted above.
c) A maximum of three (3) flammable liquid storage cabinets adjacent to each other (the boundary is applicable to the ends of the outer 2 cabinets and the fronts and backs of the cabinets).
d) A minimum of 100 feet separation between groups of cabinets within the same fire area.
e) NOTE: Flammable liquid storage rooms are exempted from the total cabinet limit, and are limited by design capacity requirements.
f) The maximum number of cabinets within a 2-hour fire rated area shall not exceed a storage capacity of 600 gallons, unless additional minimum 1-hour fire rated separation is provided.
g) Be separated by a noncombustible wall or located 5 feet or more from any aisle that is used for emergency egress unless written approval is given by Fire Protection Department. A copy of the written approval shall be
conspicuously displayed on the cabinet or within the boundaries for the cabinet.
h) Be easily accessible for firefighting operations.
i) Provide a minimum of a 40B:C rated portable fire extinguisher located within 30 feet of the storage area.
2. Flammable Liquid Storage Cabinet Storage guidelines:
a) Store only closed containers one tier high per shelf within the cabinet, not to exceed 15 gallons per shelf.
b) Store quantities less than or equal to the rating / listing of the cabinet. c) Store all flammable liquids within the cabinet [(hazard of 3 or 4 in the fire
quadrant of the NFPA diamond or HMIS square (MSDS) material storage class (A)].
d) Combustible liquids may be, but are not required to be stored within the cabinet [(rated hazard of 1 or 2 in the fire quadrant of the NFPA diamond or HMIS square (MSDS) material storage class (B)].
e) Combustible liquids shall not displace or supersede requirements for flammable liquids to be in the cabinet.
f) Flammable aerosols shall be stored in a flammable liquid cabinet.
g) Flammable liquids which are not used in daily operations shall be stored in approved containers within the cabinet, or shall be removed from the KCP. h) Combustible materials, such as empty cardboard boxes, paper, wood, tote
boxes, and rags shall not be stored in flammable liquids cabinets. i) NOTE: Special cases allowed in the cabinets are multi-part kits, large
quantities of small size containers (tubes of glue and collapsible containers). j) Store any flammable liquid not in use during the shift in an approved
flammable liquid cabinet. This includes aerosol spray cans, red plastic squeeze bottles, flammable liquid safety cans, and dip cans.
k) Do not store other materials in the cabinet. 3. Storage Outside of Buildings
Storage of flammable liquids outside of the buildings of the KCP must comply with NFPA 30 and the requirements listed below:
Container storage (five gallon containers and less) a) Containers must be:
(1) NRTL (UL/FM) approved metal Safety Cans
(2) Have self-closing (spring) lids and flash arrestor screens (3) Maximum sized container allowed is five gallons.
Quantity limited to amount needed for efficient operations (2-day supply) not to exceed 25 gallons (five 5-gallon containers). c) Storage location:
(1) No storage inside office trailers, material storage trailers, or on the roof.
(2) Maintain separation distances from important combustible buildings and or materials of not less than fifty (50) feet.
(3) Maintain separation distances from important noncombustible storage or solid masonry walls with no penetrations of not less than twenty-five (25) feet.
(4) Important buildings would be considered any NNSA-owned buildings, buildings with high value or mission critical functions, and buildings not owned or operated by/for the KCP. (Construction trailers would not be considered an important building.)
(5) Outside storage must be protected from weather, theft, and provide spill containment (i.e., a watertight, leak-proof job box or flammable liquid cabinet secured such that wind will not tip over the box/cabinet).
(6) Flammable cabinet or box shall be clearly labeled "Flammable -Keep Fire Away" and contain the NFPA Diamond label (Gasoline is 1-3-0) on all four sides.
(7) Flammable/combustible liquids must be separated from flammable gas (LP, acetylene, etc.) and oxygen cylinders by at least 20 feet. (8) Storage location must not impede or present a danger to any building exit route, including exits from construction trailers.
(9) Area surrounding flammable storage areas shall be kept clear of all trash, debris, weeds, and other combustible material.
(10) Storage location must be easily accessible for fire fighting operations.
(11) Provide a minimum of a 40B:C portable fire extinguisher located within 30 feet of the storage area.
(12) Portable extinguisher shall be inspected and maintained per NFPA 10 Portable Fire Extinguishers.
(13) For outside storage in containers larger than 5 gallon (drums, portable tanks, etc.) containers or quantities exceeding 25 gallons, please contact KCP Fire Protection and Environmental Operations Departments for required guidance.
4. Using Flammable Liquids
a) Refueling operations shall be conducted outside in an area that is safe to dispense flammable liquids.
b) Report spills promptly to Environmental Operations at extension 7745 or dial SPIL.
c) Contact Fire Protection Department prior to taking flammable liquids onto the roof. A FPD escort is required for all flammable liquid operations on the roof. d) Contractor personnel must be trained on the appropriate use and hazards of
the flammable liquid.
F. Hot Work (Welding, Cutting, Grinding, or Spark-Producing Activities) 1. Hot Work Permits shall be required for each shift.
2. Where hot work operations are to be performed, a Hot Work Permit shall be obtained from the Fire Protection Department (extension 3711). Permits shall be required for each hot work job performed on the site.
3. A Hot Work Permit can be obtained by calling the Fire Protection Department (X3711). The name of the requester and company performing the work, location of work, and type of work to be performed shall be required when requesting a Hot Work Permit.
4. Any painting or solvent activities must be at least 40 feet from any hot work. 5. Ensure the proposed hot work site is free of flammable or combustible materials.
6. Work that includes use of portable power saws and grinders on metal or spark-producing surfaces shall require a Hot Work Permit.
7. All welding shall be shielded to protect personnel from rays, sparks, and slag. Fire blankets shall be used to protect flammables and combustibles from sparks and slag.
8. Hot work shall not be performed on ducts, plenum chambers, and dust-collecting systems until the units have been shut down, the duct cleaned, and all combustible lining and covering materials removed from that portion of the duct being cut or welded. Approval from the Project Engineer must also be received.
