P23 MELT CONFINED SPACE LOG

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Camron Brooks
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1 SPACE DESCRIPTION DESIGNATION ACCEPTABLE ENTRY PROCEDURES # NON PERMIT #1 BELT PIT Conveyors with moving parts, pulleys, gears & rollers Conveyors are guarded. If guards are removed, lockout of system must be completed FREQUENCY OF ENTRY DAILY "LOCATED OUTSIDE IN MELT CHARGE YARD" # COKE BIN #1 # COKE BIN #2 # CARBIDE BIN # MISC BIN NON PERMIT VENTILATION REQUIRED Dusty atmosphere Possible low oxygen Mechanical belt feed into bin Engulfment in contents Entrapment in tapered bottom Fall hazard - 25 ft deep 1. Mutli gas air monitor APPROXIMATELY 2 X YEAR Empty contents of bin Close and lock bottom sliding door Lockout belt/conveyor. 1. Lock out #3 feed belt. A. If #3 belt needs to be run because work is to be done during production, skip #1 and go onto #2. B. If #3 belt is locked out go to step #5. 2. Raise the plow blade on #3 belt that feeds the bin to be worked in. A. Chain and lock plow blade in the up position. 3. Install blanking over the chutes feeding the bin to be worked in. A. Weld expanded or sheet steel over the chute so no material could enter the bin if the chained and locked up plow blade would somehow fall. 4. Open the bottom door on the bin to ensure it is empty. 5. Look down into the bin from the top along #3 belt to make sure the contents of the bin are all removed. 6. Close the bottom door on the bin and lock out the two ball valves (CONTINUED ON NEXT ROW)

2 # (CONTINUED) NON PERMIT (CONTINUED FROM PREVIOUS ROW) DAILY # COKE BIN #1 # COKE BIN #2 # CARBIDE BIN # MISC BIN 7. Open the side door on the bin. A. This door is located on the north side. B. The door is heavy, use a cumalong to assist in opening the door. 8. Using an air monitor, check the quality of the air in the bin. A. If the air quality is good, continue onto step #10. B. If the air is bad, DO NOT ENTER, contact your foreman or supervisor. 9. Entry to the bin can be performed and work inside the bin can be completed. 10. If prolonged work is to be done in the bin, the bottom door of the bin may need to stay open to remove fines that slowly build up. If this is the case, follow the following steps. A. With the bottom door closed and locked out, build a temporary deck in the bottom of the bin at any level above the door. Use expaned metal to allow any fines to fall through the deck. B. Unlock the ball valves for the bottom door cylinder and open the door. # LIMESTONE BIN PERMIT Dusty atmosphere Possible low oxygen Mechanical belt feed into bin Engulfment in contents Entrapment in tapered bottom Fall hazard - 25 ft deep Empty contents of bin Lock out belt/conveyor Pre entry and continuous air monitoring within acceptable limits 1. Multi gas Air Monitor 2. Body harness attached to Mechanical retrieval Approx. 2 times per year # METAL HOPPER #1 # METAL HOPPER #2 # COKE HOPPER #1 # COKE HOPPER #2 NON PERMIT 1. Portable ladder 2 X YEAR Lock out steel shaker, Remelt transfer shaker, Pig iron shaker, IF HOPPER IS CHANGED lower charge hydraulics, overhead cranes and fasten hopper OUT doors closed. Dusty atmosphere Fall hazard greater than 4 feet Empty contents of hopper and close bottom door - or lock open. Lock out limestone belt A and B, coke belt, carbide belts A and B, and mics. Belt A and B.

3 # # PERMIT NON DAILY Engulfment in contents ENTRY NOT EXPECTED SPILL CONTAINMENT TANK Fall hazard device 3. Portable ladder Empty contents Rinse tank # CHARGE BUCKET #1 # CHARGE BUCKET #2 NON PERMIT 1. Portable ladder WEEKLY Metal Hopper drops material into bucket & may engulf. Fall hazard greater than 4 feet deep. Empty contents of bucket. Secure bottom doors. Lockout crane magnet. Lockout bucket to prevent unexpected movement CHARGE BUCKET PIT # CUPOLA (bottom doors closed) NON PERMIT Charge bucket moving in and out of pit. Lockout DAILY Lockout charge bucket Temperature/heat Fall hazard 100 ft. Mechanical & electrical equipment used for repair work Possible high or low oxygen Non production entry Bottom drop procedures Allow to cool Lockout charge system, oxygen system, blast blowers, level gauges, cupola cap, charger shield, cupola emergency sprays air and emergency sprays water. Spray and purge a minimum of 3 hours 2. Body harness attached to the spyder basket.

4 # # NON PERMIT 1. Body harness attached to the spyder basket. SHUT DAILY DOWN CUPOLA Fall hazard if entered from the top (bottom doors open) Non production entry Bottom drop procedures Allow to cool Lockout charge system, oxygen system, blast blowers, level gauges, cupola cap, charger shield, cupola emergency sprays air and emergency sprays water. Spray and purge a minimum of 3 hours # CUPOLA WIND DRUM Temperature/heat Extreme forced air (CO) Airborne combustible dust Possible high or low oxygen 2. Body harness attached to a safety rope for retrieval ANNUAL FOR RELINING CONTRACTED REFRACTORY WORK Non production entry Bottom drop procedures Allow to cool Lockout blast blower # TON FURNACE (P2) # TON FURNACE (P3) NON PERMIT Fall hazard when bottom open & inductors removed Temperature/heat Dust/noise during relining process Hydraulics 1. Fall protection if inductors are removed. 2. Portable ventilation. 3. GFCI for portable equipment. ANNUAL FOR RELINING CONTRACTED REFRACTORY WORK Lockout hydraulic mechanism of furnace. Pin furnace to prevent movement. Block opening in bottom of furnace when inductors are removed. Fall protection required if shoveling out the furnace, with bottom open Continuous ventilation during refractory work. GFCI for portable equipment used inside of the furnace.

5 # # NON PERMIT 1. 2 Way Radio DAILY FOR DAILY CLEAN UP Electrical hazards near the inductors # Fall hazard into the pit (15 feet) FURNACE PITS Movement of the furnace Lockout hydraulics to the furnace and electrical to the inductors. External barrier to prevent a fall hazard into the pit. No Entry into the furnace pit when Hot Metal Carriers are overhead. # CUPOLA GAS TAKE OFF DUCT Temperature/heat (CO) - Exhausts off cupola Fall hazard into cupola Airborne combustible dust Possible low or high oxygen Electrical hazard - vent fan and switches. 2 X YEAR Non production entry Complete cupola shut down Allow to cool and ventilate for 4 hours Lockout: * 2 Exhausters * 6 Natural gas lines (3 pilot & 3 main gas) * 4 Burner disconnect # NON-CONTACT WATER TANK (Cupola loop) *New installation 3/02 Fall hazard 15 feet. Engulfment in water.. Possible low oxygen.. ANNUAL Empty contents of tank Lockout cooling tower pumps, Cupola and Tuyere city water valves and make up water Possible low oxygen

6 # # NON PERMIT Mechanical and electrical hazards 1. 2 Way Radio MONTHLY DAILY Overhead fans and gears #1 SOUTH # #2 Center # #3 NORTH COOLING TOWERS (non contact system water) 1.Lockout the tower fans. 2.Lock out water line valves. # PUMP LIFT STATION U-DRAIN Engulfment Unknown contents (outside drainage collection) Fall hazard (15' deep) Mechanical hazard Possible low oxygen Flammble (natural gas). device *DOOR SHOULD BE KEPT LOCKED ON BUILDING TO PREVENT UNAUTHORIZED ENTRY Remove contents of pit. Lockout pumps. ELECTRICAL PIT NORTH OF P2 OFFICES NON PERMIT Pit is 5 feet deep, 15 feet long, holds trays and cables, runs under driveway 1. Entrance barricade 2. Portable Ladder ANNUAL NON PERMIT

7 # NON PERMIT DAILY Waste Sand Silo Fall hazard Steep bottom Engulfment in contents Dusty atmosphere Mechanical hazard Empty contents of silo. Lockout mixer Lockout runner collection and emissions transporters device. 3. Portable Blower AS NEEDED # VEHICLE MAINTENANCE STEAM CLEAN SUMP PIT Possible hazardous Atmosphere, depending on cleaners in use, or drainage into pit. Mechanical Sump pump Fall hazard 5.5' device AS NEEDED # COMBUSTION CHAMBER Dust (CO, natural gas) Fall hazard into drop out Temperature / Heat device Cupola / Melt system shutdown procedure Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours. Lockout: * 2 combustion blowers * Burners & blowers * Gas valves Run exhauster when needed for cooling and ventilation.

8 # # PERMIT NON SHUT DAILY DOWN Dust COMBUSTION CHAMBER Flammable DROP OUT device (CO, natural gas) Fall hazard from combustion chamber Temperature / Heat Cupola / Melt system shutdown procedure Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours. Lockout: * 2 combustion blowers * Burners & blowers * Gas valves * Lock Drop Chute in the OPEN position Run exhauster as needed for cooling and ventilation # DUCT WORK FROM COMBUSTION CHAMBER TO RECOUP # DUCT WORK FROM COMBUSTION CHAMBER TO WASTE HEAT TOWER Dust (CO, natural gas) Fall hazard from combustion chamber Temperature / Heat Cupola / Melt system shutdown procedure Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours. Lockout burner ball valves & bottom device

9 # # PERMIT NON SHUT DAILY DOWN WASTE HEAT TOWER Dust (carbon monoxide) Temperature / Heat Struck by steel shot Mild bottom 2. Body Harness atteched to life line Cupola / Melt system shutdown procedure Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours. Run exhauster as needed for additional ventilation and heat reduction. Lockout ball rain feed.. # RE-COUPERATOR TOWER Dust (carbon monoxide) Temperature / Heat Struck by Steel Shot Mild bottom 2. Body Harness atteched to life line Cupola / Melt system shutdown procedure Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours. Run Exhauster as needed for additional ventilation and heat reduction. Lockout ball rain feed..

10 # # , # PERMIT NON (2) SHUT DAILY DOWN DUCTWORK FROM RECOUP/WASTE HEAT TO BAGHOUSE INLET Dust CO Temperature / Heat Exposure to enviro-blend 2. Ladder # , # DUCTWORK FROM BAGHOUSES TO EXHAUSTERS (NORTH & SOUTH) Cupola / Melt system shutdown procedure Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours. Lockout enviro-blend pin system # , # # , # # , # # , # # , # # , # #1 BAGHOUSE THRU #12 BAGHOUSE Dust CO Temperature / Heat Engulfment Mechanical Tapered Bottom 1.Multi gas air monitor 2.Portable ladder 3.Portable floor (Morton open grip)

11 # NON PERMIT Cupola / Melt system shutdown procedure DAILY BAGHOUSES (12) Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours. Empty contents of space. Lockout: * Disable transporters and close dampers * Close & lock main transport air supply valve * Bleed off air pressure * Close ball valves (2) and lock Alternate Procedure: If cupola system will not be shutdown and baghouse must be entered (ie: plugged b/h, or transport problems) follow this alternate procedure. Bottom/Side Hatch Entry: Lockout: * Disable transporter and close dampers * Close & lock main transport air supply valve Open Door/Hatch and allow to cool (approx. 20 minutes) Alternate Procedure: If cupola system will not be shutdown and baghouse must be entered (ie: leak detection, or bag change) follow this alternate procedure. Top Hatch Entry: Lockout: * Disable transporter and close dampers * Close & lock main transport air supply valve * Bleed off air pressure * Close ball valves (2) and lock Open top 3 hatch doors and allow to cool (approx minutes)

12 # # NON PERMIT DAILY Possible toxic atmosphere, air is drawn off runners and furnace 1.Multi gas air monitor EVERY 2-3 WEEKS FOR RUNNER COLLECTION area. 2. Portable Lighting CLEANING. BAGHOUSE Mechanical hazard - auger in bottom under floor grate 3. 2 Way Radio Tapered bottom - guarded by floor grate BAG REPLACEMENT AS Silica may be over PEL NEEDED. Additional fire hazard and toxic atmosphere with Hot Work situations Airborne combustible dust Engulfment Fall hazard greater than 4 feet 1. Lockout auger and inflow blower. *Hot Work not allowed with bags in place. *Continuous ventilation and air monitoring for Hot Work. 2. Air monitoring pre-entry and during entry must be acceptable. # HOT OIL TANK RESERVOIR TANK A & B # OIL EXPANSION TANKS TANK A & B 1. Engulfment 2. Temperature / Heat 3. Possible low oxygen 4. Fall hazard greater than 4 feet (slippery from contents) 1. Cupola / Melt system shutdown procedure 2. Empty contents (oil) - may need to rinse tank 3. Lockout of oil pumps device 3. Portable ladder 4. 2 Way Radio

13 # HOT BLAST DUCT PERMIT NON 1. Dust SHUT DAILY DOWN Body harness attached life line/rope # (CO) 3. 2 Way Radio RECOUP TO WIND DRUM 4. Temperature / Heat 5. Possible flammable gas # Engulfment BLAST BLOWER TO RECOUP 7. Fall Hazard TOWER 8. Hot Temps 9. Mechanical moving parts. 1. Cupola / Melt system shutdown procedure 2. Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours. 3. # NORTH EXHAUSTER FAN 2. Body harness attached to a life line # SOUTH EXHAUSTER FAN Mechanical fan movement Cupola / Melt system shutdown procedure. Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours.. Lockout fan. # EAST BLAST BLOWER # WEST BLAST BLOWER Mechanical fan movement Cupola / Melt system shutdown procedure. Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours.. Lockout blower. 2. Body harness attached to a life line 3. 2 Way Radio

14 # # PERMIT NON NO ENTRY DAILY EXPECTED 1. Possible low oxygen level 1000 GALLON CHEMICAL 2. Possible toxic atmosphere STORAGE TANK FOR DUST device COVER BOLTED SHUT 3. Engulfment TREAT NOTIFY SAFETY 4. Fall hazard DEPARTMENT IF AN 5. Chemical exposure to 9119 polymer ENTRY IS EVER NEEDED # GALLON STORAGE TANK FOR DUST TREAT 1. Empty contents of tank. 2. Block incoming flow. 3. Lockout pump & related equipment. 4.. # EXHAUST STACK Mechanical fan movement 2. Body harness attached to a life line 3. 2 Way Radio 1. Cupola / Melt system shutdown procedure. 2. Cool & Ventilate - stop melt, purge system cool for a minimum of 4 hours Lockout blower.

15 # OFFICE - WEST WING SEWER PERMIT NON 1. Multi gas monitor AS DAILY NEEDED. 1. Fall Hazard Greater than 4 feet. PUMP LIFT STATION 2. Barricade 2. Possible (sewage). 3. Harness and mechanical retrieval system 1. Mechanical retrieval. 2. Electrical : Lockout related equipment. 3. Provide External Barricade. 4. Ventilate using portable blower. 5. Continuous air monitoring with multi gas air monitor. # , # # , # # , # # , # NON-PERMIT 1. Excessive air flow. 2. Natural gas line. 3. Mechanical 1. Lock out related equipment 1.Multi gas Air monitor As needed Air Make Up Units 100 Ton Man Cooler ( ) 90 Ton Man Cooler ( ) NON-PERMIT 1. High velocity air 1.Multigas Air Monitor As needed 1. Lockout related equipment. Coarse Grain Separator # Extreme temperature Possible toxic atmosphere Fall Hazard Entrapment Flammable gas, vapor or mist 1.Multigas Air Monitor 2.Body harness attached to mechanical retrieval 3.2-way radio 4.Portable ladder As needed 1. Purge and allow system to cool for 4 hours. 2. Lock out related equipment (burners, 2 combustion blowers, gas valves) 3. Pre entry and continuous monitoring must be within acceptable limits.

16 # PERMIT NON Possible toxic atmosphere,. 1.Multigas Air Monitor As DAILY needed Manholes/StormSewers Located throughout the facility and surrounding outside areas Contains material that can engulf Fall hazard in some of the manholes >4 foot Entrapment Animals and/or inscects 2.Body harness 3.Lifeline 4.2-way radio 5.Portable lighting 6.Mechanical retrieval Accepatable air prior to entry Lock out any related equipment (fill pipe) Empty contents prior to entry

Key Question. What is the most important aspect to the removal and cleaning of material?

Key Question. What is the most important aspect to the removal and cleaning of material? Objectives Increase plant maintenance issue awareness Understand how and where new technology can make workplace safer Ideas to discuss cleaner and more efficient Key Question What is the most important