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1 JULY 2007
Volume 1, Issue 2 July 2007
Mill Outage Safety
By: Adam DeMouy
The 2007 Palatka outage will be one of the
largest in recent memory. Contractors will be on-
site in large numbers to assist GP employees with
specialized work that will be occurring mill wide.
Normally, shutdown and startup of
manufacturing facilities are the most dangerous
times of the year for employees and contractors, it
does not have to be that way. With good planning,
execution and personal responsibility, plant outages
can be completed without injuries.
During the first week of the outage, GP will have
as many as 670 contract employees during days and
approximately 370 on-site at night. As the outage
goes on, those totals will drop significantly but will
still be substantial. By the end of the scheduled
outage on August 7th
, GP Palatka will clock nearly
186,000 work hours.
The mill will be a busy place for most of the
month. No matter how hectic things may become,
no matter how tight the schedule, we need to keep
our attention first and foremost on SAFETY.
"No Job Is So Important That
It Cannot Be Done Safely!"
PPaallaattkkaa PPuullpp && PPaappeerr
OOppeerraattiioonnss
DDeeddiiccaatteedd ttoo tthhee eemmppllooyyeeeess
ooff GGPP PPaallaattkkaa OOppeerraattiioonnss
IInnssiiddee tthhiiss iissssuuee::
OOuuttaaggee NNoottiiccee……………………........11
MMiillll oouuttaaggee sscchheedduullee......22
##55 TTMM HHoooodd
RReeppllaacceemmeenntt……....………………..33--44
KKrraafftt PPrroojjeeccttss…………..……55--66
RReeccoovveerryy BBooiilleerr……..........77--88
LLoocckkoouutt TTaagg OOuutt……..……......99
HHoott WWoorrkk…………..........................1100
CCoonnffiinneedd SSppaaccee && SSaaffee
WWoorrkk PPeerrmmiittss…………......1111--1133
SSaaffeettyy AAuuddiittss……........1144--1155
HHeeaatt SSaaffeettyy……..……......1166--1177
NNeewwsslleetttteerr SSttaaffff......……1188
2 JULY 2007
Palatka Mill Outage Schedule
#5 TM Hood Replacement
3 JULY 2007
By: Adam DeMouy
The largest outage project in tissue area is the
new aircap system on the yankee dryer for
number 5 tissue machine. The aircap system that
is currently on the machine was installed in
March 1988. Useful life expectancy for an aircap
system is typically fifteen years. With constant
maintenance and dedication from all GP
employees, number five paper machine’s yankee
dryer aircap system has continued to add value.
“Frequent repairs have resulted in excessive
costs to maintain safe operation of the system
over the past five years ($745,000). Repairs
have encompassed multiple replacements of
ductwork from the burner chamber to the aircap,
face damper, expansion joints, burner refractory,
and nozzle boxes,” said lead project engineer
Greg Garris. “As a result of a past ductwork
failure, the crossover capability has been
removed from the current system. Prolonged
operation at maximum temperature has resulted
in embrittlement of the nozzle boxes which have
now become irreparable without wholesale
replacement of the aircap inner structure.”
The outage is scheduled for fourteen days to
remove the old aircap and install the new hood.
A new burner house extension and economizer
room will be required to provide the necessary
space for the new burner chambers, cascade fan
unit, duct recirculation system, and heat recovery
system; which will make the aircap system more
reliable.
Below is a diagram of the new yankee dryer
aircap system:
4 JULY 2007
The venture fits Palatka’s goal to replace/repair
structurally deteriorating assets and to
regain/improve drying efficiency and lower our
cost per ton. The total investment in the Aircap
System project is $8,505,000 dollars.
“The project will allow the business to
continue production on this high efficiency asset
and avoid the need for production at another
higher-cost mill,” explained John Floyd,
manager support services.
Jason Claro, #5 Tissue Machine 3rd
Hand
Bubba Dixon, #5 Tissue Machine Tender
Number five tissue machine tender, James
(Bubba) Dickson, says “The current aircap
system restricts #5 tissue machine.”
The current systems ability can only be pushed
so far and impacts the quality of product made
by the machine. “I want to make more quality
rolls because the more quality I put out, more
pride I take in my job,” explained Dixon. “With
a new aircap system going into place, moral is
increasing.”
5 JULY 2007
Kraft Machine Projects
Kraft paper operations will be working on a number of projects during the
July outage. # 1 kraft paper machine will have the winder drive replaced and
the Deculator primary cleaner cones replaced. On # 2 kraft paper machine,
the main focus will be on carb bearing installation and dryer balancing. For
more insight into the logistics of these significant operations, Kevin
Muglach, Asset Availability Leader, gives a few points of interest:
KPM1
1. Winder Drive Replacement— This is a major capital project which
will eliminate obsolete drive equipment and offer increased tension
control for the operators. The existing drives are no longer supported
by the OEM, and spare parts are not available. With the new drive
design, the winder will be equipped with state-of-the-art technology
that is compatible with the drive technology currently in use on #2
kraft winder.
2. Deculator Primary Cleaner Cone Replacement— All of the
primary cleaner cones underneath the deculator will be replaced this
year during the annual outage. Many of the cones in this position are
due for replacement. There are also several cones that have been
taken out of service due to previous failures. In addition to replacing
the cones, we will also install a new jumper line from the secondary
cleaner to the fan pump suction. This will de-bottleneck the primary
cleaner cones by reducing the inlet pressure to the cones. This system
will allow #1 kraft machine to run at target speeds and headbox flow
rates without risking primary cleaner cone failures in the future.
6 JULY 2007
KPM2
1. Carb Bearing Installation— 18 SKF CARB (style torroidal roller
bearings) will be installed on #2 machine during the annual outage
this year. These bearings will be installed on the tending side of the
dryer cans in the 1-A, 1-B and 2nd
dryer sections. The CARB style
bearings are designed to allow axial growth of 10-12% of the bearing
width without detrimental effects to bearing performance. This is key
to the prevention of bearing failures on dryer cans due to the thrust
load caused by thermal growth that occurs when the cans are warmed
to operating temperature. This is an ongoing project, which will
eventually result in CARB bearings on every dryer can in the tending
side position.
2. Dryer Balancing— #2 machine will have an extensive dryer
balancing project performed this year to eliminate vibration in the
machine frame. Excessive vibration causes bearing failures, loose
frame bolts, gear issues, frame oil leaks and a multitude of other
mechanical issues. These problems occur at high speeds when the
machine is at its optimum run rate.
7 JULY 2007
By: Adam DeMouy
The 2007 recovery boiler outage is expected to
be the largest one yet for Palatka operations.
With a major rework of the existing boiler, GP
Palatka will have its hands full with the
replacement of the entire super heater and
economizer sections during the outage. Total
estimated cost is around $24 million.
The current recovery boiler at GP Palatka
operations is a 1976 Alstom unit. In 1991, the
lower furnace walls were replaced with a
combination of composite tubes with an
additional band of chromized tubing in the upper
furnace. The air system was upgraded to an
Alstom three level system with concentric
tangential tertiary air. In 1995, sixteen additional
super heater screen platens were added.
The existing super heater and economizer are
original. During the past four years, there have
been a number of tube failures in both the
economizer and super heater due to a
combination of cycle fatigue and corrosion.
To increase efficiency and reliability, the
project will also include an upgrade of the
combustion air system to a modern vertical air
system in order to improve combustion and
efficiency. By implementing the upgrade,
Palatka operations will be able to reduce the
potential for future super heater corrosion and
pluggage problems.
With the use of a high alloy, Sanicro 28,
composite tubing, corrosion rates that normally
occur over time will be far less. The objective of
the capital project is to restore unit availability
while eliminating the problems associated with
the existing super heater and economizer.
Along with the capital rebuild project of the
recovery boiler, the Palatka mill will also be
adding all new sootblower control system
upgrades and eight new soot blowers; which will
keep the boiler cleaner then before.
A new over-fire system is being added which
will optimize combustion capabilities and
improve boiler efficiency.
Recovery Boiler Composite Tubing
Along with the super heater and economizer
installation, two water wall panels will be
replaced.
According to Billy Payne, electrical engineer
III, when the mill goes cold on July 23, all
normal mill functions will be gone, the first cold
outage since March of 2001.
“The mill will be a very eerie place to be
around with nothing running,” said Eddie
Williams, project engineer III. “Any employee
who was not present during the last cold outage
will be in for a surprise.”
Generators will be the only source of
electricity in the mill.
“Imagine a hurricane just hit and knocked all
power out in your house--that’s what it will be
like during the cold outage,” added Payne.
All areas of the mill, even tissue converting and
kraft operations, will have no power for thirty-
two hours. With NO ELECTRICITY during this
time, planning for alternative sources of
electricity, drinking water and other vital
8 JULY 2007
necessities will be essential for the outage to
proceed safely.
“Greg Miller and Wayne Ford have done an
excellent job planning the recovery and
mechanical outages,” said Dan Casey, head of
maintenance planning.
With 200 employees from National Boiler
Services working with GP employees, all
employees will have to be watchful for safety
related situations.
“I realize the many frustrations that will occur
during the hectic outage, but we all have to
remember that we are all on the same team,
trying to reach the same goal,” said Jeff
McClellan, power plant #4 operator.
The cold outage is necessary to inspect and
repair the over-worked switch gears. The cold
outage requires all generators and boilers shut
down. In addition, the Florida Power & Light
feeds will be down for fourteen hours for
electrical inspections to occur throughout the
mill.
When the dead bus (electrical junctions)
inspections are ongoing, back feed issues will
be on each employee’s mind. If someone were
to run a generator at one area of the mill, that
current would carry to a different part of the
mill, possibly injuring a fellow co-worker.
Safety will be a top priority in keeping the
outage moving forward. All generators and
welding machines capable of back feeding
power into the GP Palatka system must have a
permit to operate. Please see Billy Payne for
the necessary permits.
Power will be down from 7:00am –
10:00pm on July 23. Power will be back on in
tissue converting at 10:00pm, along with the rest
of the mill. The dead bus inspections must be
done every six years to meet compliance
standards.
With a thirty-day outage, employees will have
the time to check and re-check new equipment
being installed; making sure every piece of new
equipment is ready for optimal running ability.
When the project is completed on August 8, the
recovery boiler will be completely overhauled,
resulting in better reliability and efficiency for
the mill.
Power House & Outage supplies
Time Table for Dead Bus Inspection
(Mill Power Outage)
Kraft Machine Outages
 #1 Kraft Machine- July 19th
 #2 Kraft Machine- July 25th
Tissue Machine Outages
 #3 Tissue Machine- July 26th
 #4 Tissue Machine- July 24th
 #5 Tissue Machine- July 27th
9 JULY 2007
By: Palatka Mill Safety Team
Lockout Policy
Here are a few important reminders from our
Lockout Policy that we need to remember as we
prepare for the outage. Proper lock and tag can
ensure that we are safe while we work on the
equipment in our mill.
4.5 Protection of Non-GP Personnel: Outside
service personnel (contractors, service
representatives, vendors, etc.) must comply with
Georgia-Pacific lockout requirements. These
contractors must submit proof that all of their
employees have been trained in the OSHA and
GP lockout/tagout requirements and that they
understood this training prior to beginning work.
4.6 If any Non GP personnel apply an energy
isolating device to any lockout device, it must be
accompanied by a personal or departmental lock
applied by the appropriate, authorized GP
employee. Isolation of any energy source may
be done only by GP personnel who are trained
and authorized to perform this task. The only
exceptions are hoist and crane contractors that
are qualified may operate local disconnects
without GP personnel.
13.7 Each area must have a list of lock
boxes/rings with the location of each lock
box/ring on the list. Copies of this list will be
available to persons pulling the switches and
working on the equipment.
13.8 All areas should ensure that all lock
boxes/rings are located where they are safely
accessible and nothing will obscure the vision of
the sheet.
Please Note: We have found several lockout
locks being used on personal lockers and other
places. Our lockout policy defines personal lock
as:
Personal Locks: To be utilized by authorized
employees to isolate energy sources. A personal
lock is silver Master lock with a 2½ shank and
one key. These locks must not be used for
anything other than lockout.
If you are using a lockout lock for anything other
than lockout, please remove the lock and replace
it with the proper lock. Thanks
Valve Tagging: We have spent a lot of time and effort to ensure that valves in many areas of the mill are
properly tagged. We will continue this process in all areas. Always ensure that when you remove a tag from
any valve for any reason, you put the tag back when work is completed. This is especially important as we
go into our outage. Proper tagging of all equipment is another tool we have to ensure we do our jobs safely.
“The only successful Outage is a Safe Outage”.
10 JULY 2007
By: Palatka Mill Safety Team
Hot Work Safety
As you prepare for the upcoming outage, please review our Hot Work policy, section 3-13 of our Policy and
Procedure manual (found on the Safety Page) with all employees that will be involved in hot work
activities. Our safety policies and rules were established to ensure that we maintain a safe work environment
for all employees. Please follow them to help us complete our 2007 outage safely.
Hot Work Policy
Hot Work Procedures Around Combustible Materials/Vapors
Welding or performing hot work on operating equipment that
contains combustible vapors is prohibited. Use of steam or other
methods to exclude oxygen is not permitted as a method to allow
welding or hot work. The size or duration of the welding work is not
a consideration.
Welding on blow tanks, accumulator tanks, or any other vessels
where turpentine vapor or other combustible vapor could gather
shall be done only after the vessel has been completely purged of
fumes. Vessels, pipelines, or other containers previously containing
flammable/combustible materials shall be purged, washed, and
tested with appropriate direct read instruments prior to and during
any hot work. In situations where simple purging or washing is
unable to clean the vessel enough to maintain the atmosphere below
10% of the lower flammable limit of the former contents, additional
cleaning and purging are required in addition to continuous air
monitoring.
For work inside of confined spaces, all Georgia-Pacific Confined
Space Entry Standard requirements apply. All such spaces will be
isolated and locked out per equipment specific lockout procedures.
If welding, fresh air shall be supplied to workers inside of vessels
using forced air ventilation. Where toxic welding vapors may be
generated, appropriate air purifying respiratory protection is also
required. Work is not permitted in confined spaces that are oxygen
deficient or IDLH.
Equipment having held combustible dusts, chips, or materials capable of generating noxious vapors or
fumes upon heating will be completely emptied to remove all traces of combustible material prior to
welding on or inside of the equipment.
11 JULY 2007
By: Palatka Mill Safety Team
Confined Space Definition: (NOTE: must meet all three of the following)
1. So configured that the space can be bodily entered.
2. Not designed for continuous employee occupancy.
3. Limited or restricted means of entry or egress.
Permit-Required Confined Space (Meets the 3 above plus any of the following):
1. Contains or has the potential to contain a hazardous atmosphere.
2. Contains a material that has the potential for engulfing an entrant.
3. Internal configuration that might cause an entrant to be trapped or asphyxiated by inwardly
converging walls or floor that slopes downward and tapers to a smaller cross section.
4. Contains any other recognized serious safety or health hazard.
Permit-Required Confined Space Roles:
1. Entry Supervisor: Person responsible for determining if acceptable entry conditions are present,
for authorizing entry, overseeing entry operations, and for terminating entry as required.
 Knows the hazards including signs, symptoms, and consequences of the exposure.
 Verifies that the entry permit is complete, all tests have been conducted and all procedures and
equipment are in place before allowing entry to begin.
 Verifies that rescue services are available and that the means for summoning them are operable.
 Remove unauthorized individuals who enter or attempt to enter the space.
 Ensures that acceptable entry conditions are maintained throughout the entry.
 Terminates entry and cancels the permit when the operations have been completed, or a condition that
is not allowed under the permit arises.
2. Authorized Entrants:
 Understand potential hazards.
 Use equipment properly.
 Communicate with attendant regularly.
 If the unexpected occurs—alert the attendant.
 Exit immediately if hazard develops.
 Alert the attendant whenever an entrant recognizes any warning sign or symptom of exposure to a
dangerous situation or the entrant detects a prohibited condition.
 Evacuate the confined space when:
o An order to evacuate is given by the attendant or entry supervisor.
o Entrant recognizes any warning sign or symptom of exposure to a dangerous situation.
o Entrant detects a prohibited condition.
o Evacuation alarm is activated (i.e. Confined Space Monitor alarms).
12 JULY 2007
3. Attendant:
 Maintain stationed outside the permit space; monitor entrants.
 Knows the hazards including signs, symptoms, and consequences of exposure.
 Continuously maintains accurate count of entrants in permit space.
 Remains outside the permit space during entry until relieved by another attendant.
 Summon emergency services.
 Keep unauthorized persons away and prevent entry.
 Inform entrants and entry supervisor if unauthorized persons have entered the permit space.
 Performs non-entry rescues when applicable.
 Performs no additional duties that might interfere with primary duty to monitor and protect entrants.
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Safe Work Permits—A Tool for Safety Success!
As we prepare to enter the annual outage, refreshing ourselves on the requirements involving Safe Work
Permits (SWP) will help us prevent injuries to ourselves and our co-workers. Ultimately, SWP’s are one of
the many tools at our disposal to help plan safety into every job we do. The process starts and ends with
each and every one of us.
The Safe Work Permit process focuses on non-routine jobs--jobs/tasks that are performed less often than
daily/weekly in frequency. Due to the infrequency of these tasks, remembering all of the hazards
associated with each step can involve risks that we have the potential to overlook.
Developing a formal Job Safety Analysis (JSA) to evaluate the hazards associated with each of the job
steps that need to be performed, and implementing control measures will ensure that we prevent our fellow
employees from getting hurt. Please review the SWP procedures below:
When are Safe Work Permits Required?
Anytime we open process vessels equipment, or piping.
Performing Maintenance of Equipment.
Stopping Leaks involving hazardous materials or dangerous conditions.
Conducting activities involving LO/TO, Hot Work, Line Breaking/Blinding, energized electrical work,
or confined space entry.
Completing excavations, penetrations, or critical lifts.
ALL non-routine work activities.
Exceptions:
Routine adjustment of in-service equipment or job activities that occur everyday/week.
Production lockouts or routine maintenance work that occurs at least weekly.
Routine activities that occur in designated, documented controlled areas (shops, storage areas, &
fabrication areas).
13 JULY 2007
Remember: The Equipment Owner signs the permit indicating that the
machinery/equipment has been properly prepared, isolated, locked-out and
work area hazards addressed (housekeeping) before releasing the
equipment to maintenance or contractors. The Permit Acceptor, Safety
Lead and each worker signing onto the permit are signifying (via their
signature) that they have read the JSA for the job and agree that the
precautions taken are sufficient. If not, discuss with the parties involved
and address concerns before starting the job/task.
As we exercise the SWP process in each of our areas, this is an opportunity to review all of the
safety-related aspects about the jobs we are about to perform and ensure we plan for safety!
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Confined Space Valves
Palatka Pulp & Paper Mill
14 JULY 2007
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By: Brooke Martin industrial hygiene specialist
Auditing Safety During The Outage
Some of the most common audit items to
look for during the outage are:
1. PPE. Audit the areas for proper PPE.
Make sure that hardhats are being worn, eye
protection, gloves when handling iron and
wood. Crews that are blasting tanks should
be aware of the hazards and provided with
the proper protective clothing. Slicker pants
are not to be stuffed into boots.
2. Welding. When welding, a protective
shield is required to protect the eyesight of
others that are in the area. Check the hot
work permit.
3. Welding rigs. Exposed terminals on
machine must have protective boots
covering them. Check the welding cables for
exposed wiring and improper splicing.
Shrink-wrap is legal for a splice. Regular
tape is not.
4. Hot work. Check the permit to see if
filled out properly. Make sure the firewatch
is attentive to the job. Question the firewatch
to see if he/she knows their duties. The
firewatch is required to wear an orange vest.
Ask if they have been trained on the use of a
fire extinguisher, and make sure one is
handy.
5. Electrical cords. All extension cords are
required to have GFCI protection. Check the
cords for broken insulation, taped splices,
and grounding prong. The cords are to be
protected from traffic running over them.
Make sure the cords are used in a manner
that does not create a walking hazard. Check
area for housekeeping.
6. Fall protection. The number one killer in
the construction industry is falls. When body
harness is in use, make sure the lanyard is
tied off on something that will support
5,000lbs. Example: don’t want to find one
tied off to a fluorescent light fixture that
would not support 10 pounds. (Required if
over 4’ off of any surface)
7. Confined space. When a confined space
has been entered, be sure the space has an
attendant at/near the opening. The hole-
watch is to wear a green vest. Check the
entry permits to be sure everyone in the
space is listed. Ask the hole-watch about
their training.
8. PSM. Check to ensure that everyone
inside the PSM area has a sticker. Ask for
names and check to ensure they are signed
in.
9. Contractor stickers. Randomly ask how
they got the sticker. They are supposed to go
through orientation. Sometimes they don’t.
We need to know if the sticker was just
given to them.
10. Confined space. While at the space,
check to make sure the air is being
monitored inside. Also, we check to make
sure that any equipment such as gasoline
powered generators; welders, etc. are not
located near openings. Be sure that your
generator isn’t too close and fills the space
15 JULY 2007
with carbon monoxide. It could take up to
two hours to clear the “CO” from the space.
11. Lockout. Tags are to be legible. Check
to see if locks are put on individually (not
locked to another lock). Also, be sure the
employee’s name & company name is on
the tag.
12. Lights. All mobile equipment, including
vehicles, scooters, cherry pickers, etc., must
have lights on after dark. (Front and back).
Vehicles with flashing lights visible from
the rear may use reflectors or reflective tape
in the rear in lieu of running lights.
13. Barricading. Ensure proper color
barricade tape is used and that barricade tags
are in place.
14. PPE around liquor, caustic. Should
have slicker, boots and eye protection.
Slicker should not be inside boots.
15. Speed. Monitor speed of vehicles
(10mph) and look for improper parking.
16. Worker observations. Observe workers
for overheating, body position, and safe
work procedures. All contractor employees
must be “clean shaven”.
17. Housekeeping. Areas should be orderly,
clean and free of tripping hazards. Also look
for proper use of ladders and scaffolding.
18. Chemicals. Chemicals must be
approved through the new substance review
process prior to being brought into the Mill.
A Material Safety Data Sheet (MSDS) must
be turned in to the project coordinator who
will then submit a new substance review for
approval.
19. Employee attitudes. Everyone needs to
treat each other as you wish to be treated.
We all have a job to do during the outage
and we don’t have time to deal with “out of
line attitudes”. This will not be tolerated.
We have already had one contractor
employee removed from the mill, due to not
complying with GP rules and a bad attitude.
Let’s work together to make this a
successful outage!!!
20. Extra-Important. Be sure to cover this
with each contractor employee: No alcohol
(hot or cold) or drugs can be on GP
property. This includes the point that
vehicles and people enter the mill complex
as well as the contractor parking lot. If
found, the employee will be removed from
the mill site immediately. Also remember
that no firearms of any sort are allowed on
company property.
16 JULY 2007
By: GP Intranet
Hot Environments and Your Health
Certain safety problems are common to hot
environments. Heat tends to promote
accidents due to the slipperiness of sweaty
palms, dizziness, or the fogging of safety
glasses. Also, wherever there is molten
metal, hot surfaces, steam, etc., the
possibility of burns from accidental contact
also exists.
Aside from these obvious dangers, the
frequency of accidents in general appears to
be higher in hot environments than in more
moderate environmental conditions. One
reason is that working in a hot environment
lowers the mental alertness and physical
performance of an individual. Increased
body temperature and physical discomfort
promote irritability, anger, and other
emotional states which sometimes cause
workers to overlook safety procedures or to
divert attention from hazardous tasks.
Excessive exposure to a hot work
environment can bring about a variety of
heat-induced disorders as well:
Heat Stroke: Heat stroke is the most serious
of health problems associated with working
in hot environments. It occurs when the
body's temperature regulatory system fails
and sweating becomes inadequate. The
body's only effective means of removing
excess heat is compromised with little
warning to the victim that a crisis stage has
been reached.
A heat stroke victim's skin is hot, usually
dry, red or spotted. Body temperature is
usually 105 degrees or higher, and the
victim is mentally confused, delirious,
perhaps in convulsions, or unconscious.
Unless the victim receives quick and
appropriate treatment, death can occur.
Any person with signs or symptoms of heat
stroke requires immediate hospitalization.
However, first aid should be immediately
administered. This includes removing the
victim to a cool area, thoroughly soaking the
clothing with water, and vigorously fanning
the body to increase cooling. Further
treatment at a medical facility should be
directed to the continuation of the cooling
process and the monitoring of complications
which often accompany the heat stroke.
Early recognition and treatment of heat
stroke are the only means of preventing
permanent brain damage or death.
Heat Exhaustion: Heat exhaustion includes
several clinical disorders having symptoms
which may resemble the early symptoms of
heat stroke. Heat exhaustion is caused by the
loss of large amounts of fluid by sweating,
sometimes with excessive loss of salt. A
worker suffering from heat exhaustion still
sweats but experiences extreme weakness or
fatigue, giddiness, nausea, or headache.
In more serious cases, the victim may vomit
or lose consciousness. The skin is clammy
and moist, the complexion is pale or flushed,
and the body temperature is normal or only
slightly elevated. In most cases, treatments
involve having the victim rest in a cool place
and drink plenty of liquids.
Victims with mild cases of heat exhaustion
usually recover spontaneously with this
treatment. Those with severe cases may
require hospitalization.
17 JULY 2007
Heat Cramps: Heat cramps are painful
spasms of the muscles that occur among
those who sweat profusely in heat, drink
large quantities of water, but do not
adequately replace the body's salt loss. The
drinking of large quantities of water tends to
dilute the body's fluids, while the body
continues to lose salt. Shortly thereafter, the
low salt level in the muscles causes painful
cramps. The affected muscles may be part of
the arms, legs, or abdomen, but tired
muscles (those used in performing the work)
are usually the ones most susceptible to
cramps. Cramps may occur during or after
work hours and may be relived by taking
salted liquids by mouth.
Fainting: A worker who is not accustomed
to hot environments and who stands erect
and immobile in the heat may faint. With
enlarged blood vessels in the skin and in the
lower part of the body due to the body's
attempts to control internal temperature,
blood may pool there rather than return to
the heart to be pumped to the brain. Upon
lying down, the worker should soon recover.
By moving around, and thereby preventing
blood from pooling, the patient can prevent
further fainting.
Heat Rash: Heat rash, also known as
prickly heat, is likely to occur in hot, humid
environments where sweat is not easily
removed from the surface of the skin by
evaporation and the skin remains wet most
of the time. The sweat ducts become
plugged, and a skin rash soon appears.
When the rash is extensive or when it is
complicated by infection, prickly heat can
be very uncomfortable and may reduce a
worker's performance. The worker can
prevent this condition by resting in a cool
place part of each day and by regularly
bathing and drying the skin.
Transient Heat Fatigue: Transient heat
fatigue refers to the temporary state of
discomfort and mental or psychological
strain arising from prolonged heat exposure.
Workers unaccustomed to the heat are
particularly susceptible and can suffer, to
varying degrees, a decline in task
performance, coordination, alertness, and
vigilance. The severity of transient heat
fatigue will be lessened by a period of
gradual adjustment to the hot environment
(heat acclimatization)
18 JULY 2007
Celebrating 60 years of Palatka Pride!
Great Paper- Great Products- Great People- Great Putnam
Attention Employees: Graduation picture deadline for
submitting pictures to the newsletter has been extended to
July20. Please send them to Adam DeMouy in the
Administration Building or e-mail them. Phone (EXT 4460).
Palatka Now Staff
Managing Editor: Jeremy
Alexander
Editor: Adam DeMouy
Phone: 386-329-0062
Fax: 386-328-0014
Email:
jeremy.alexander@gapac.com
adam.demouy@gapac.com

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Palaka Now July Outage Issue 2007

  • 1. 1 JULY 2007 Volume 1, Issue 2 July 2007 Mill Outage Safety By: Adam DeMouy The 2007 Palatka outage will be one of the largest in recent memory. Contractors will be on- site in large numbers to assist GP employees with specialized work that will be occurring mill wide. Normally, shutdown and startup of manufacturing facilities are the most dangerous times of the year for employees and contractors, it does not have to be that way. With good planning, execution and personal responsibility, plant outages can be completed without injuries. During the first week of the outage, GP will have as many as 670 contract employees during days and approximately 370 on-site at night. As the outage goes on, those totals will drop significantly but will still be substantial. By the end of the scheduled outage on August 7th , GP Palatka will clock nearly 186,000 work hours. The mill will be a busy place for most of the month. No matter how hectic things may become, no matter how tight the schedule, we need to keep our attention first and foremost on SAFETY. "No Job Is So Important That It Cannot Be Done Safely!" PPaallaattkkaa PPuullpp && PPaappeerr OOppeerraattiioonnss DDeeddiiccaatteedd ttoo tthhee eemmppllooyyeeeess ooff GGPP PPaallaattkkaa OOppeerraattiioonnss IInnssiiddee tthhiiss iissssuuee:: OOuuttaaggee NNoottiiccee……………………........11 MMiillll oouuttaaggee sscchheedduullee......22 ##55 TTMM HHoooodd RReeppllaacceemmeenntt……....………………..33--44 KKrraafftt PPrroojjeeccttss…………..……55--66 RReeccoovveerryy BBooiilleerr……..........77--88 LLoocckkoouutt TTaagg OOuutt……..……......99 HHoott WWoorrkk…………..........................1100 CCoonnffiinneedd SSppaaccee && SSaaffee WWoorrkk PPeerrmmiittss…………......1111--1133 SSaaffeettyy AAuuddiittss……........1144--1155 HHeeaatt SSaaffeettyy……..……......1166--1177 NNeewwsslleetttteerr SSttaaffff......……1188
  • 2. 2 JULY 2007 Palatka Mill Outage Schedule #5 TM Hood Replacement
  • 3. 3 JULY 2007 By: Adam DeMouy The largest outage project in tissue area is the new aircap system on the yankee dryer for number 5 tissue machine. The aircap system that is currently on the machine was installed in March 1988. Useful life expectancy for an aircap system is typically fifteen years. With constant maintenance and dedication from all GP employees, number five paper machine’s yankee dryer aircap system has continued to add value. “Frequent repairs have resulted in excessive costs to maintain safe operation of the system over the past five years ($745,000). Repairs have encompassed multiple replacements of ductwork from the burner chamber to the aircap, face damper, expansion joints, burner refractory, and nozzle boxes,” said lead project engineer Greg Garris. “As a result of a past ductwork failure, the crossover capability has been removed from the current system. Prolonged operation at maximum temperature has resulted in embrittlement of the nozzle boxes which have now become irreparable without wholesale replacement of the aircap inner structure.” The outage is scheduled for fourteen days to remove the old aircap and install the new hood. A new burner house extension and economizer room will be required to provide the necessary space for the new burner chambers, cascade fan unit, duct recirculation system, and heat recovery system; which will make the aircap system more reliable. Below is a diagram of the new yankee dryer aircap system:
  • 4. 4 JULY 2007 The venture fits Palatka’s goal to replace/repair structurally deteriorating assets and to regain/improve drying efficiency and lower our cost per ton. The total investment in the Aircap System project is $8,505,000 dollars. “The project will allow the business to continue production on this high efficiency asset and avoid the need for production at another higher-cost mill,” explained John Floyd, manager support services. Jason Claro, #5 Tissue Machine 3rd Hand Bubba Dixon, #5 Tissue Machine Tender Number five tissue machine tender, James (Bubba) Dickson, says “The current aircap system restricts #5 tissue machine.” The current systems ability can only be pushed so far and impacts the quality of product made by the machine. “I want to make more quality rolls because the more quality I put out, more pride I take in my job,” explained Dixon. “With a new aircap system going into place, moral is increasing.”
  • 5. 5 JULY 2007 Kraft Machine Projects Kraft paper operations will be working on a number of projects during the July outage. # 1 kraft paper machine will have the winder drive replaced and the Deculator primary cleaner cones replaced. On # 2 kraft paper machine, the main focus will be on carb bearing installation and dryer balancing. For more insight into the logistics of these significant operations, Kevin Muglach, Asset Availability Leader, gives a few points of interest: KPM1 1. Winder Drive Replacement— This is a major capital project which will eliminate obsolete drive equipment and offer increased tension control for the operators. The existing drives are no longer supported by the OEM, and spare parts are not available. With the new drive design, the winder will be equipped with state-of-the-art technology that is compatible with the drive technology currently in use on #2 kraft winder. 2. Deculator Primary Cleaner Cone Replacement— All of the primary cleaner cones underneath the deculator will be replaced this year during the annual outage. Many of the cones in this position are due for replacement. There are also several cones that have been taken out of service due to previous failures. In addition to replacing the cones, we will also install a new jumper line from the secondary cleaner to the fan pump suction. This will de-bottleneck the primary cleaner cones by reducing the inlet pressure to the cones. This system will allow #1 kraft machine to run at target speeds and headbox flow rates without risking primary cleaner cone failures in the future.
  • 6. 6 JULY 2007 KPM2 1. Carb Bearing Installation— 18 SKF CARB (style torroidal roller bearings) will be installed on #2 machine during the annual outage this year. These bearings will be installed on the tending side of the dryer cans in the 1-A, 1-B and 2nd dryer sections. The CARB style bearings are designed to allow axial growth of 10-12% of the bearing width without detrimental effects to bearing performance. This is key to the prevention of bearing failures on dryer cans due to the thrust load caused by thermal growth that occurs when the cans are warmed to operating temperature. This is an ongoing project, which will eventually result in CARB bearings on every dryer can in the tending side position. 2. Dryer Balancing— #2 machine will have an extensive dryer balancing project performed this year to eliminate vibration in the machine frame. Excessive vibration causes bearing failures, loose frame bolts, gear issues, frame oil leaks and a multitude of other mechanical issues. These problems occur at high speeds when the machine is at its optimum run rate.
  • 7. 7 JULY 2007 By: Adam DeMouy The 2007 recovery boiler outage is expected to be the largest one yet for Palatka operations. With a major rework of the existing boiler, GP Palatka will have its hands full with the replacement of the entire super heater and economizer sections during the outage. Total estimated cost is around $24 million. The current recovery boiler at GP Palatka operations is a 1976 Alstom unit. In 1991, the lower furnace walls were replaced with a combination of composite tubes with an additional band of chromized tubing in the upper furnace. The air system was upgraded to an Alstom three level system with concentric tangential tertiary air. In 1995, sixteen additional super heater screen platens were added. The existing super heater and economizer are original. During the past four years, there have been a number of tube failures in both the economizer and super heater due to a combination of cycle fatigue and corrosion. To increase efficiency and reliability, the project will also include an upgrade of the combustion air system to a modern vertical air system in order to improve combustion and efficiency. By implementing the upgrade, Palatka operations will be able to reduce the potential for future super heater corrosion and pluggage problems. With the use of a high alloy, Sanicro 28, composite tubing, corrosion rates that normally occur over time will be far less. The objective of the capital project is to restore unit availability while eliminating the problems associated with the existing super heater and economizer. Along with the capital rebuild project of the recovery boiler, the Palatka mill will also be adding all new sootblower control system upgrades and eight new soot blowers; which will keep the boiler cleaner then before. A new over-fire system is being added which will optimize combustion capabilities and improve boiler efficiency. Recovery Boiler Composite Tubing Along with the super heater and economizer installation, two water wall panels will be replaced. According to Billy Payne, electrical engineer III, when the mill goes cold on July 23, all normal mill functions will be gone, the first cold outage since March of 2001. “The mill will be a very eerie place to be around with nothing running,” said Eddie Williams, project engineer III. “Any employee who was not present during the last cold outage will be in for a surprise.” Generators will be the only source of electricity in the mill. “Imagine a hurricane just hit and knocked all power out in your house--that’s what it will be like during the cold outage,” added Payne. All areas of the mill, even tissue converting and kraft operations, will have no power for thirty- two hours. With NO ELECTRICITY during this time, planning for alternative sources of electricity, drinking water and other vital
  • 8. 8 JULY 2007 necessities will be essential for the outage to proceed safely. “Greg Miller and Wayne Ford have done an excellent job planning the recovery and mechanical outages,” said Dan Casey, head of maintenance planning. With 200 employees from National Boiler Services working with GP employees, all employees will have to be watchful for safety related situations. “I realize the many frustrations that will occur during the hectic outage, but we all have to remember that we are all on the same team, trying to reach the same goal,” said Jeff McClellan, power plant #4 operator. The cold outage is necessary to inspect and repair the over-worked switch gears. The cold outage requires all generators and boilers shut down. In addition, the Florida Power & Light feeds will be down for fourteen hours for electrical inspections to occur throughout the mill. When the dead bus (electrical junctions) inspections are ongoing, back feed issues will be on each employee’s mind. If someone were to run a generator at one area of the mill, that current would carry to a different part of the mill, possibly injuring a fellow co-worker. Safety will be a top priority in keeping the outage moving forward. All generators and welding machines capable of back feeding power into the GP Palatka system must have a permit to operate. Please see Billy Payne for the necessary permits. Power will be down from 7:00am – 10:00pm on July 23. Power will be back on in tissue converting at 10:00pm, along with the rest of the mill. The dead bus inspections must be done every six years to meet compliance standards. With a thirty-day outage, employees will have the time to check and re-check new equipment being installed; making sure every piece of new equipment is ready for optimal running ability. When the project is completed on August 8, the recovery boiler will be completely overhauled, resulting in better reliability and efficiency for the mill. Power House & Outage supplies Time Table for Dead Bus Inspection (Mill Power Outage) Kraft Machine Outages  #1 Kraft Machine- July 19th  #2 Kraft Machine- July 25th Tissue Machine Outages  #3 Tissue Machine- July 26th  #4 Tissue Machine- July 24th  #5 Tissue Machine- July 27th
  • 9. 9 JULY 2007 By: Palatka Mill Safety Team Lockout Policy Here are a few important reminders from our Lockout Policy that we need to remember as we prepare for the outage. Proper lock and tag can ensure that we are safe while we work on the equipment in our mill. 4.5 Protection of Non-GP Personnel: Outside service personnel (contractors, service representatives, vendors, etc.) must comply with Georgia-Pacific lockout requirements. These contractors must submit proof that all of their employees have been trained in the OSHA and GP lockout/tagout requirements and that they understood this training prior to beginning work. 4.6 If any Non GP personnel apply an energy isolating device to any lockout device, it must be accompanied by a personal or departmental lock applied by the appropriate, authorized GP employee. Isolation of any energy source may be done only by GP personnel who are trained and authorized to perform this task. The only exceptions are hoist and crane contractors that are qualified may operate local disconnects without GP personnel. 13.7 Each area must have a list of lock boxes/rings with the location of each lock box/ring on the list. Copies of this list will be available to persons pulling the switches and working on the equipment. 13.8 All areas should ensure that all lock boxes/rings are located where they are safely accessible and nothing will obscure the vision of the sheet. Please Note: We have found several lockout locks being used on personal lockers and other places. Our lockout policy defines personal lock as: Personal Locks: To be utilized by authorized employees to isolate energy sources. A personal lock is silver Master lock with a 2½ shank and one key. These locks must not be used for anything other than lockout. If you are using a lockout lock for anything other than lockout, please remove the lock and replace it with the proper lock. Thanks Valve Tagging: We have spent a lot of time and effort to ensure that valves in many areas of the mill are properly tagged. We will continue this process in all areas. Always ensure that when you remove a tag from any valve for any reason, you put the tag back when work is completed. This is especially important as we go into our outage. Proper tagging of all equipment is another tool we have to ensure we do our jobs safely. “The only successful Outage is a Safe Outage”.
  • 10. 10 JULY 2007 By: Palatka Mill Safety Team Hot Work Safety As you prepare for the upcoming outage, please review our Hot Work policy, section 3-13 of our Policy and Procedure manual (found on the Safety Page) with all employees that will be involved in hot work activities. Our safety policies and rules were established to ensure that we maintain a safe work environment for all employees. Please follow them to help us complete our 2007 outage safely. Hot Work Policy Hot Work Procedures Around Combustible Materials/Vapors Welding or performing hot work on operating equipment that contains combustible vapors is prohibited. Use of steam or other methods to exclude oxygen is not permitted as a method to allow welding or hot work. The size or duration of the welding work is not a consideration. Welding on blow tanks, accumulator tanks, or any other vessels where turpentine vapor or other combustible vapor could gather shall be done only after the vessel has been completely purged of fumes. Vessels, pipelines, or other containers previously containing flammable/combustible materials shall be purged, washed, and tested with appropriate direct read instruments prior to and during any hot work. In situations where simple purging or washing is unable to clean the vessel enough to maintain the atmosphere below 10% of the lower flammable limit of the former contents, additional cleaning and purging are required in addition to continuous air monitoring. For work inside of confined spaces, all Georgia-Pacific Confined Space Entry Standard requirements apply. All such spaces will be isolated and locked out per equipment specific lockout procedures. If welding, fresh air shall be supplied to workers inside of vessels using forced air ventilation. Where toxic welding vapors may be generated, appropriate air purifying respiratory protection is also required. Work is not permitted in confined spaces that are oxygen deficient or IDLH. Equipment having held combustible dusts, chips, or materials capable of generating noxious vapors or fumes upon heating will be completely emptied to remove all traces of combustible material prior to welding on or inside of the equipment.
  • 11. 11 JULY 2007 By: Palatka Mill Safety Team Confined Space Definition: (NOTE: must meet all three of the following) 1. So configured that the space can be bodily entered. 2. Not designed for continuous employee occupancy. 3. Limited or restricted means of entry or egress. Permit-Required Confined Space (Meets the 3 above plus any of the following): 1. Contains or has the potential to contain a hazardous atmosphere. 2. Contains a material that has the potential for engulfing an entrant. 3. Internal configuration that might cause an entrant to be trapped or asphyxiated by inwardly converging walls or floor that slopes downward and tapers to a smaller cross section. 4. Contains any other recognized serious safety or health hazard. Permit-Required Confined Space Roles: 1. Entry Supervisor: Person responsible for determining if acceptable entry conditions are present, for authorizing entry, overseeing entry operations, and for terminating entry as required.  Knows the hazards including signs, symptoms, and consequences of the exposure.  Verifies that the entry permit is complete, all tests have been conducted and all procedures and equipment are in place before allowing entry to begin.  Verifies that rescue services are available and that the means for summoning them are operable.  Remove unauthorized individuals who enter or attempt to enter the space.  Ensures that acceptable entry conditions are maintained throughout the entry.  Terminates entry and cancels the permit when the operations have been completed, or a condition that is not allowed under the permit arises. 2. Authorized Entrants:  Understand potential hazards.  Use equipment properly.  Communicate with attendant regularly.  If the unexpected occurs—alert the attendant.  Exit immediately if hazard develops.  Alert the attendant whenever an entrant recognizes any warning sign or symptom of exposure to a dangerous situation or the entrant detects a prohibited condition.  Evacuate the confined space when: o An order to evacuate is given by the attendant or entry supervisor. o Entrant recognizes any warning sign or symptom of exposure to a dangerous situation. o Entrant detects a prohibited condition. o Evacuation alarm is activated (i.e. Confined Space Monitor alarms).
  • 12. 12 JULY 2007 3. Attendant:  Maintain stationed outside the permit space; monitor entrants.  Knows the hazards including signs, symptoms, and consequences of exposure.  Continuously maintains accurate count of entrants in permit space.  Remains outside the permit space during entry until relieved by another attendant.  Summon emergency services.  Keep unauthorized persons away and prevent entry.  Inform entrants and entry supervisor if unauthorized persons have entered the permit space.  Performs non-entry rescues when applicable.  Performs no additional duties that might interfere with primary duty to monitor and protect entrants.        Safe Work Permits—A Tool for Safety Success! As we prepare to enter the annual outage, refreshing ourselves on the requirements involving Safe Work Permits (SWP) will help us prevent injuries to ourselves and our co-workers. Ultimately, SWP’s are one of the many tools at our disposal to help plan safety into every job we do. The process starts and ends with each and every one of us. The Safe Work Permit process focuses on non-routine jobs--jobs/tasks that are performed less often than daily/weekly in frequency. Due to the infrequency of these tasks, remembering all of the hazards associated with each step can involve risks that we have the potential to overlook. Developing a formal Job Safety Analysis (JSA) to evaluate the hazards associated with each of the job steps that need to be performed, and implementing control measures will ensure that we prevent our fellow employees from getting hurt. Please review the SWP procedures below: When are Safe Work Permits Required? Anytime we open process vessels equipment, or piping. Performing Maintenance of Equipment. Stopping Leaks involving hazardous materials or dangerous conditions. Conducting activities involving LO/TO, Hot Work, Line Breaking/Blinding, energized electrical work, or confined space entry. Completing excavations, penetrations, or critical lifts. ALL non-routine work activities. Exceptions: Routine adjustment of in-service equipment or job activities that occur everyday/week. Production lockouts or routine maintenance work that occurs at least weekly. Routine activities that occur in designated, documented controlled areas (shops, storage areas, & fabrication areas).
  • 13. 13 JULY 2007 Remember: The Equipment Owner signs the permit indicating that the machinery/equipment has been properly prepared, isolated, locked-out and work area hazards addressed (housekeeping) before releasing the equipment to maintenance or contractors. The Permit Acceptor, Safety Lead and each worker signing onto the permit are signifying (via their signature) that they have read the JSA for the job and agree that the precautions taken are sufficient. If not, discuss with the parties involved and address concerns before starting the job/task. As we exercise the SWP process in each of our areas, this is an opportunity to review all of the safety-related aspects about the jobs we are about to perform and ensure we plan for safety!             Confined Space Valves Palatka Pulp & Paper Mill
  • 14. 14 JULY 2007   By: Brooke Martin industrial hygiene specialist Auditing Safety During The Outage Some of the most common audit items to look for during the outage are: 1. PPE. Audit the areas for proper PPE. Make sure that hardhats are being worn, eye protection, gloves when handling iron and wood. Crews that are blasting tanks should be aware of the hazards and provided with the proper protective clothing. Slicker pants are not to be stuffed into boots. 2. Welding. When welding, a protective shield is required to protect the eyesight of others that are in the area. Check the hot work permit. 3. Welding rigs. Exposed terminals on machine must have protective boots covering them. Check the welding cables for exposed wiring and improper splicing. Shrink-wrap is legal for a splice. Regular tape is not. 4. Hot work. Check the permit to see if filled out properly. Make sure the firewatch is attentive to the job. Question the firewatch to see if he/she knows their duties. The firewatch is required to wear an orange vest. Ask if they have been trained on the use of a fire extinguisher, and make sure one is handy. 5. Electrical cords. All extension cords are required to have GFCI protection. Check the cords for broken insulation, taped splices, and grounding prong. The cords are to be protected from traffic running over them. Make sure the cords are used in a manner that does not create a walking hazard. Check area for housekeeping. 6. Fall protection. The number one killer in the construction industry is falls. When body harness is in use, make sure the lanyard is tied off on something that will support 5,000lbs. Example: don’t want to find one tied off to a fluorescent light fixture that would not support 10 pounds. (Required if over 4’ off of any surface) 7. Confined space. When a confined space has been entered, be sure the space has an attendant at/near the opening. The hole- watch is to wear a green vest. Check the entry permits to be sure everyone in the space is listed. Ask the hole-watch about their training. 8. PSM. Check to ensure that everyone inside the PSM area has a sticker. Ask for names and check to ensure they are signed in. 9. Contractor stickers. Randomly ask how they got the sticker. They are supposed to go through orientation. Sometimes they don’t. We need to know if the sticker was just given to them. 10. Confined space. While at the space, check to make sure the air is being monitored inside. Also, we check to make sure that any equipment such as gasoline powered generators; welders, etc. are not located near openings. Be sure that your generator isn’t too close and fills the space
  • 15. 15 JULY 2007 with carbon monoxide. It could take up to two hours to clear the “CO” from the space. 11. Lockout. Tags are to be legible. Check to see if locks are put on individually (not locked to another lock). Also, be sure the employee’s name & company name is on the tag. 12. Lights. All mobile equipment, including vehicles, scooters, cherry pickers, etc., must have lights on after dark. (Front and back). Vehicles with flashing lights visible from the rear may use reflectors or reflective tape in the rear in lieu of running lights. 13. Barricading. Ensure proper color barricade tape is used and that barricade tags are in place. 14. PPE around liquor, caustic. Should have slicker, boots and eye protection. Slicker should not be inside boots. 15. Speed. Monitor speed of vehicles (10mph) and look for improper parking. 16. Worker observations. Observe workers for overheating, body position, and safe work procedures. All contractor employees must be “clean shaven”. 17. Housekeeping. Areas should be orderly, clean and free of tripping hazards. Also look for proper use of ladders and scaffolding. 18. Chemicals. Chemicals must be approved through the new substance review process prior to being brought into the Mill. A Material Safety Data Sheet (MSDS) must be turned in to the project coordinator who will then submit a new substance review for approval. 19. Employee attitudes. Everyone needs to treat each other as you wish to be treated. We all have a job to do during the outage and we don’t have time to deal with “out of line attitudes”. This will not be tolerated. We have already had one contractor employee removed from the mill, due to not complying with GP rules and a bad attitude. Let’s work together to make this a successful outage!!! 20. Extra-Important. Be sure to cover this with each contractor employee: No alcohol (hot or cold) or drugs can be on GP property. This includes the point that vehicles and people enter the mill complex as well as the contractor parking lot. If found, the employee will be removed from the mill site immediately. Also remember that no firearms of any sort are allowed on company property.
  • 16. 16 JULY 2007 By: GP Intranet Hot Environments and Your Health Certain safety problems are common to hot environments. Heat tends to promote accidents due to the slipperiness of sweaty palms, dizziness, or the fogging of safety glasses. Also, wherever there is molten metal, hot surfaces, steam, etc., the possibility of burns from accidental contact also exists. Aside from these obvious dangers, the frequency of accidents in general appears to be higher in hot environments than in more moderate environmental conditions. One reason is that working in a hot environment lowers the mental alertness and physical performance of an individual. Increased body temperature and physical discomfort promote irritability, anger, and other emotional states which sometimes cause workers to overlook safety procedures or to divert attention from hazardous tasks. Excessive exposure to a hot work environment can bring about a variety of heat-induced disorders as well: Heat Stroke: Heat stroke is the most serious of health problems associated with working in hot environments. It occurs when the body's temperature regulatory system fails and sweating becomes inadequate. The body's only effective means of removing excess heat is compromised with little warning to the victim that a crisis stage has been reached. A heat stroke victim's skin is hot, usually dry, red or spotted. Body temperature is usually 105 degrees or higher, and the victim is mentally confused, delirious, perhaps in convulsions, or unconscious. Unless the victim receives quick and appropriate treatment, death can occur. Any person with signs or symptoms of heat stroke requires immediate hospitalization. However, first aid should be immediately administered. This includes removing the victim to a cool area, thoroughly soaking the clothing with water, and vigorously fanning the body to increase cooling. Further treatment at a medical facility should be directed to the continuation of the cooling process and the monitoring of complications which often accompany the heat stroke. Early recognition and treatment of heat stroke are the only means of preventing permanent brain damage or death. Heat Exhaustion: Heat exhaustion includes several clinical disorders having symptoms which may resemble the early symptoms of heat stroke. Heat exhaustion is caused by the loss of large amounts of fluid by sweating, sometimes with excessive loss of salt. A worker suffering from heat exhaustion still sweats but experiences extreme weakness or fatigue, giddiness, nausea, or headache. In more serious cases, the victim may vomit or lose consciousness. The skin is clammy and moist, the complexion is pale or flushed, and the body temperature is normal or only slightly elevated. In most cases, treatments involve having the victim rest in a cool place and drink plenty of liquids. Victims with mild cases of heat exhaustion usually recover spontaneously with this treatment. Those with severe cases may require hospitalization.
  • 17. 17 JULY 2007 Heat Cramps: Heat cramps are painful spasms of the muscles that occur among those who sweat profusely in heat, drink large quantities of water, but do not adequately replace the body's salt loss. The drinking of large quantities of water tends to dilute the body's fluids, while the body continues to lose salt. Shortly thereafter, the low salt level in the muscles causes painful cramps. The affected muscles may be part of the arms, legs, or abdomen, but tired muscles (those used in performing the work) are usually the ones most susceptible to cramps. Cramps may occur during or after work hours and may be relived by taking salted liquids by mouth. Fainting: A worker who is not accustomed to hot environments and who stands erect and immobile in the heat may faint. With enlarged blood vessels in the skin and in the lower part of the body due to the body's attempts to control internal temperature, blood may pool there rather than return to the heart to be pumped to the brain. Upon lying down, the worker should soon recover. By moving around, and thereby preventing blood from pooling, the patient can prevent further fainting. Heat Rash: Heat rash, also known as prickly heat, is likely to occur in hot, humid environments where sweat is not easily removed from the surface of the skin by evaporation and the skin remains wet most of the time. The sweat ducts become plugged, and a skin rash soon appears. When the rash is extensive or when it is complicated by infection, prickly heat can be very uncomfortable and may reduce a worker's performance. The worker can prevent this condition by resting in a cool place part of each day and by regularly bathing and drying the skin. Transient Heat Fatigue: Transient heat fatigue refers to the temporary state of discomfort and mental or psychological strain arising from prolonged heat exposure. Workers unaccustomed to the heat are particularly susceptible and can suffer, to varying degrees, a decline in task performance, coordination, alertness, and vigilance. The severity of transient heat fatigue will be lessened by a period of gradual adjustment to the hot environment (heat acclimatization)
  • 18. 18 JULY 2007 Celebrating 60 years of Palatka Pride! Great Paper- Great Products- Great People- Great Putnam Attention Employees: Graduation picture deadline for submitting pictures to the newsletter has been extended to July20. Please send them to Adam DeMouy in the Administration Building or e-mail them. Phone (EXT 4460). Palatka Now Staff Managing Editor: Jeremy Alexander Editor: Adam DeMouy Phone: 386-329-0062 Fax: 386-328-0014 Email: jeremy.alexander@gapac.com adam.demouy@gapac.com