your electrical connection - newton power station retirees · examples include conducting...

Your Electrical Connection

January 2018

Volume 16, Issue 1

Inside this issue:

VPP Cornerstones Cont. 2

Ash Pond Activity 2

Seasonal Affective Disor-der

3

S/R Slew Bearing Re-placement

4

S/R Slew Bearing Re-placement Cont.

5

S/R Slew Bearing Re-placement Cont.

6

Dumper House Fire Pro-tection Line

6

Dumper House Fire Pro-tection Line Cont.

7

CY Run Off Pond Culvert Repair

7

CY Run Off Pond Culvert Repair Cont.

8

CY Run Off Pond Culvert Repair Cont.

9

Wellness Corner 10

Upcoming Events 10

February Birthdays 10

Four Cornerstones of VPP ...Kent Schafer

I feel that our VPP team had a revelation at our last meeting. Through efforts to accomplish a goal, we might have misrepresented what VPP is really all about. I think we might have un-knowingly driven perception of VPP to the work order level where in your minds VPP=guarding or lighting or holes in electrical boxes or open flanges on tanks. The efforts that we have given toward the “punchlist” are associated with the overall effort of possibly be-coming a VPP plant, but it is just the piece that requires your plant to be OSHA compliant. For the most part, these punchlist items are not above and beyond items. However, I can see how some items are perceived as adding very little true safety value even though the OSHA stand-ard requires them and how this perception could make you question if our resources have been prioritized properly or even question the value of the VPP process. So I thought I would go back to the basics and go over the four cornerstones of VPP and a few of my thoughts on how they can and will benefit the station and more importantly you as an employee. These cornerstones include Management Commitment and Employee Involvement, Worksite Analy-sis, Hazard Prevention and Control, and Training.

Training

I think everyone understands the value of good training. The expectation for a VPP plant is to have a training program that ensures employees are fully trained and competent to conduct their work tasks safely and efficiently. A comprehensive training program for contractors is also required. When I went around to the work groups recently to discuss 2018 goals, the need for improved training was a consistent message. VPP doesn’t tell us how to get there, but it does hold us accountable to the end result. That result is a trained workforce that can perform their tasks safely, recognize hazards and know how to mitigate those hazards, and understand the plant systems to be able to maintain and operate them safely. Our days of a training department are likely behind us so we collectively are going to have to figure out the training piece. It will require thought and creativity from all of us to come up with something that works.

Worksite Analysis

It is critical for a quality safety program to have methods and techniques for identifying haz-ards and issues that could potentially put the employees and equipment at risk. These meth-ods need to be both leading and lagging, with the emphasis on leading and being proactive. Some examples include job briefs/job hazard analysis, routine inspections, wellness, manage-ment of change, hazard reporting, incident investigation, industrial hygiene sampling, and oth-ers. We have been around the world it seems in this area and have performed a lot of good practices and initiatives. However, we have struggled to maintain what works and these good practices fall off the table. I feel VPP will give us a little more consistency because we will be required to measure and report on our program’s effectiveness. We will stick with what works and scrap what doesn’t instead of just bouncing around from one initiative to the next.

Hazard Prevention and Control

Well this is a necessary evil from my perspective. Procedures…..Once we identify hazards, we have to have ways to control those hazards. LOTO, Confined Space, HazCom, etc. I feel like we maybe focus too much time in this area, probably because I feel like I spend too much time in this area. The bottom line is a good safety program has to have good procedures that

Number of Days Since Last...

First Aid 66

Recordable 12

Lost Time 636

Numbers based on January 24, 2018, includes plant and contractors.

Safety Stats:

Your Electrical Connection Volume 16, Issue 1

Four Cornerstones of VPP (cont.)

Ash Pond Activity ...Adam Green

Many of you may have noticed some activity out in the Primary Ash Pond cell over the past few weeks. Our materials han-dling contractor, Headwaters, is working to reclaim the bottom ash aggregate in the ash pond and market it to multiple clients for a variety of applications. As part of our company’s Coal Combustion By-Product (CCB) Beneficial Reuse initiative, we have been encouraged to explore the many ways this material can be used. Similar to fly ash, bottom ash can be used in numerous construction and manufacturing applications, including structural and engineering fill, aggregate for concrete and asphalt products, and general reclamation purposes. In our case, Effingham and Jasper Counties have shown interest in the material’s anti-skid properties, and plan to use it for snow and ice traction control on roads.

Headwaters has brought in equipment that screens the material into aggregates of various sizes. The operator loads the bottom ash into the screening machine, and it travels up a conveyor to the inlet of the screening column. It is then sifted down through multiple screens, which sort the particles into different sizes. Multiple conveyors discharge the end-products onto three stockpiles. The finer variety resembles sand and could be used as filler for structural applications, while to coarser product contains aggregates ranging from ¾” to 1” and could be used in anything from landscaping to road base.

While this project is temporary, longer-term operation of the screening equipment may be considered if we find that there is a market for this product. Please let management know if you are aware of a specific use that could generate demand for bot-tom ash.

are effective and protect our employees. We are constantly trying to make them “better”, which I am sure can always be ar-gued. Similar to the analysis methods above, VPP keeps our procedures at the forefront as we have to review and report an-nually on their effectiveness and our compliance to them.

Management Commitment and Employee Involvement

My opinion is that this cornerstone is what creates the value in going down the VPP journey. As an employee, I know manage-ment has a commitment to the safety program and allowing me to be involved at whatever level I choose to be. I have control of my own destiny from a safety perspective. I have a voice. This management style has not always been here. If VPP is to stay, it has to stay. Employee involvement in the safety program has improved over the years and hopefully it will continue. Examples include conducting inspections, providing training, performing incident investigations, committees, performing job hazard analyses, etc. I feel this cornerstone speaks more to the culture that we already have. I think there are just some rough edges here and there that need polished and I think VPP will help us with that.

Everyone will have their own thoughts and perspectives about VPP and our path forward. I appreciate the opportunity to share some of mine with you.


Seasonal Affective Disorder ...Rick Wolford

Thought I would share this article I came across the other day in the Wellness Magazine written by Diane Lang con-cerning the Winter Blues. Hope some of you might find some of this info useful.

8 Ways to Prevent the Winter Blues Called SAD (Seasonal Affective Disorder)

There are several people who experience a change of moods during the fall and winter months, particularly a feeling of depression and sadness. Typically when the weather gets warmer, these feelings will begin to lessen. If you are feeling under the weather during the cold winter months but not sure if you are having seasonal disorder, you can check to see if you are experiencing certain symptoms related to the disorder. Diane Lang, a therapist, positive living speaker, author, and life coach, shares some of the symptoms associated with SAD and eight ways to help prevent the winter blues.

Seasonal Affective Disorder (SAD) Symptoms:

1. Feelings of sadness, hopelessness and anxiety during the winter months. 2. Feeling fatigue, loss of energy, trouble concentrating and unmotivated. 3. The feelings of sadness, fatigue, isolated, etc. that start out mild and become more severe as the winter

progresses. 4. Change in appetite and sleeping habits.

Social withdrawal - loss of interest in social activities and hobbies. Some people tend to “hibernate” during the winter months. They don’t leave their house very often during the winter months and stop socializing and enjoying their daily activities. They start feeling isolated, lonely and depressed. Watch out for this pattern.

“The cause of SAD is still unknown but we know environmental factors play a big role,” Diane Lang says. “A person who lives in an area near a lake can get ‘the lake effect’ where he gets so much snow and very little sun all winter, re-sulting in SAD. We also know that SAD can run in the family - genetics play a role. Seasonal affective disorder is more common in women and we usually see symptoms starting in young adulthood.”

Treatment and How to Prevent

There are different treatment options available for SAD and even ways to help prevent SAD or at least the severity of it.

1. Light Therapy - we know that increased sunlight helps improve the symptoms of seasonal disorder. There are certain lights you can buy called “Light Therapy Box,” which mimic outside light and help you lift your mood and spirits.

2. Psychotherapy - a therapist can help you identify your negative thoughts and behaviors and help change them. A therapist can also help you find good coping skills to feel better.

3. Spend some time outdoors to grab some natural light - take a morning or afternoon walk and take time to sit in the sun to help lift your spirits. Even if the weather is cold and snowy, we do know that being outside in the winter months is beneficial.

4. Exercise - every time we exercise we produce endorphins while reducing stress hormones. This gives us a boost of happiness.

5. Bring the outdoors inside - open up the shades and curtains. Move your desks and chairs near the window to bring the sunlight in doors.

6. Don’t let winter make you feel trapped. Make weekly plans to have fun whether it’s dinner with friends or catching a movie, just make sure to laugh and socialize. Surround yourself with family and friends to give the extra support you need.

7. Plan a vacation where the weather is warm and the sun is shining. If you feel a sense of isolation and lone-liness in the winter months, setting up vacation time in warm, sunny spots can help and give you something to look forward to.

8. Meds - Doctors have prescribed anti-depressants that have worked well for some patients that suffer with more severe SAD symptoms.


Stacker/Reclaimer Slew Bearing Replacement ...Scott Stewart

The work to replace the stacker slew bearing commenced on October 25th when the superintendent for Enerfab, Ro-land Gilmore and an operator arrived on site and started preparing the worksite. Material for the job started arriving on the 25th and continued throughout the duration of the project. Two trailers were used by the contractors for an office and a break area. The management team for the project consisted of Roland Gilmore, John Ogburn (site supervisor, day shift for Enerfab), Tracy Herron (site su-pervisor, night shift for Enerfab), Marc Hubbard (Metso Minerals Technical Service) and Ray Zimaska (Metso Min-eral Technical Service)

After the initial setup by Enerfab, the work of supporting the stacker and preparing the stacker for the lift began. This is when the first major issue was discovered. The webs of the girders supporting the counterweight were found bowed 5/8” out of plumb. This condition required the addition of 5 gussets per girder in addition to the 4 gussets that were part of the original scope of work. The gussets will prevent further bowing of the girders. The installation required the south tower support pad to be enlarged in order to install a support tower under the coun-terweight during the installation of the gussets. The boom side of the stacker was also supported by a support tower during the installation of the gussets. This additional work added a week to the schedule.

Once the gussets were installed on the counterweight girders, the stacker was moved to the east and the coal yard equipment operators washed down the stacker. The south support tower was relocated to the position to jack up the rotating assembly so the slew bearing could be replaced. The relocation efforts were supported by the plant through the use of the crane. Once the south tower was relocated, the stacker was repositioned over the sup-port towers. The stacker was secured and the boom and counterweight were anchored.

The stacker rotating carriage was lifted using eight 150 ton jacks. Once the carriage was raised, plates were installed

under the boom and counterweight structure and the stacker carriage was lowered onto these plates. With the stacker carriage lifted into position and properly supported, the slew bearing removal process commenced. The roll-ing elements were removed first. Then the upper and low-er races were removed. The mounting surfaces for the races were cleaned and prepared for the installation of the new bearing races. The new races were installed, and then the new rolling elements and spacers were posi-tioned in the lower race. Grease was applied to all the rolling elements and packed in the race.

In conjunction with the slew bearing replacement, the slew drives were worked on and one luffing cylinder was re-placed. The slew drives were removed and sent offsite for inspection, removal of the pinion shafts, and installation of the new pinion shafts in one existing gear reducer and in the new gear reducer. The slew drives were returned to the plant for installation. The luffing cylinder was removed and the new cylinder installed and checked out.

The final steps of the slew bearing replacement were to lower the stacker carriage onto the new rolling elements, install new bearing covers, connect the lube lines, re-install the two slew drives and operate the stacker. After the lube lines were connected and the lube pump returned to service, the pump developed a severe leak. The pump was taken out of service and the lube system modified so grease could be pumped from the lube cart to the slew bearing. After the support towers were taken down the stacker was placed in service to check out the operation. There were a few hiccups due to some limit switches that required adjustment. After the limit switch issues were addressed the stacker was returned to service and has been operating satisfactorily. The stacker slews smoothly along with the boom. This job was successful due to the knowledge and skill of all the contractors and plant em-ployees that were involved. My hat is off to all those that were involved!

Completed south tower pad Completed north tower pad


Stacker/Reclaimer Slew Bearing Replacement (Cont.)

South tower being erected Counterweight being supported

The boom supported by the north tower. New gussets installed for the counterweight.

Tow and jacks on north side of stacker. 50T chain falls used to secure stacker.

Removing slew drive Removing slew gear and slew bearing


Stacker/Reclaimer Slew Bearing Replacement (Cont.)

New slew bearing rolling elements and spacers New slew drive reducer and pinion shaft New luffing cylinder

New slew bearing covers with lube lines attached Stacker back to normal and work complete

Dumper House Fire Protection Line Addition ...Chris Rauch

The project to add an additional fire protection line to the dumper house was completed prior to year-end by Badger Daylight-ing and the plant welders. Badger Daylighting began the project on November 13 by hydro excavating the material between the dumper house and the FGD fire protection line. Badger was not able to remove all of the material via hydro excavation due to strength of the material at a couple of locations as the old scrubber sludge had formed with the rock to create a com-pound that was near concrete strength and this material had to be removed via the back-hoe.

The hydro excavation process saved numerous unplanned underground repairs by allowing them to be excavated safely in-stead of digging them out with an excavator and causing damage to that item (pipe, cable or conduit). After the excavation work was completed, the welders installed the HDPE (high-density polyethylene) pipe. They installed a 6” HDPE line from the scrubber fire loop to the dumper house with post indicating isolation valves at each end. The roadways and the locomotive building rail had the HDPE pipe sleeved with a 12” carbon steel pipe to provide further protection to the HDPE pipe. The fire protection line was released and leak tested on December 6. The line was covered with sand and rock prior to the deep freeze hitting the area.

I would like to thank the welders for their dedication to the project to allow it to be completed under budget and prior to year-end.


Dumper House Fire Protection Line Addition (Con.t)

Coal Yard Run Off Pond Culvert Repair ...Chris Rauch

The project to repair the coal yard run off pond culvert was completed prior to year-end by Plocher Construction with assistance from the Coal Yard employees and Blankenship Construction. As you may recall the 42” corrugated metal pipe (CMP) culvert failed several years ago washing out a portion of the road on the world South side of the dumper house bypass track. The initial plan was to slip-line the failed 42” culvert with a 36” high-density polyethylene (HDPE) pipe. Well, we ended up slip-lining the CMP with a 32” Snap-Tite HDPE pipe instead of a 36” HDPE pipe. The new 32” pipe will actually provide more flow through it then the original 42” CMP.

Plocher was awarded the project on 11/7 and arrived on-site to start the project on 11/27. In order to reline the CMP, they had to access the CMP from the run-off pond side which would require them to stop the flow of material into the drainage vault, remove about 5’ deep coal fines from the run-off pond, and to build a temporary roadway across the run-off pond to the culvert. With CY assistance in damming the upstream 36” drainage pipe, they installed inflatable bags into the 24” CMP from the CY slurry pond and into the 36” HDPE drainage pipe from the transfer house basin area. After the bags were inflated, they were successful in stop-ping the drainage flow into the run-off pond and then the dig-out of the fines started. Blankenship’s operator and CY operators assisted in hauling the fines away from the pond. After the material was removed and the temporary road in-stalled, Plocher installed an engineered shoring box with plate sides to prevent material from falling into the area to provide personnel protection while working near the pipe. Next, Bodine cleaning services was utilized to hydroblast

clean the 42” CMP. The cleaning dredged out rope, conduit, old tools and a lot of coal fines. The cleaning also degraded the lower section of the pipe further than before and caused their tool to get stuck a few times during the cleaning. After Plocher was satisfied with the cleaning, they setup to start building and shoving the Snap-Tite piping together and, to their and my amazement, the pushing of the piping was ra-ther easy and uneventful. The biggest obstacle was trying to snap the pieces of pipe together prior to pushing them into the 42” CMP. The drawings showed that the 42” CMP was approximately 178’ long and the plan was to install 8 pieces of the 24’ Snap-Tite pipe in place and cut off the ex-cess. After pushing 7 pieces of pipe, the pipe was inside the drainage vault and sticking half way into the pond. So the actual distance installed ended up being 150’ after they cut off a significant portion on the 7th piece of pipe. They added a 42” CMP from the original failure towards the pond. After the installation of grout piping, they injected grout between the 42” CMP and the 32” Snap-Tite pipes. After the grout-ing, Plocher removed the temporary access in the run-off pond and re-sloped the pond embankment. Plocher, with CY assistance, also built the road back up next to the dump-er house by-pass rail. The last step was to deflate the bags in the 24” and 36” drainage pipes and to remove them to allow water to re-enter the pond thru the new 32” pipe, which was done on 12/14/17. Plocher left the pond em-bankment access easier for future run-off pond cleanings.

I would like to thank the CY team for their support during the project to minimize costs from Plocher to allow the project to be completed under budget and prior to year-end.


Coal Yard Run Off Pond Culvert Repair (Cont.)


CY Run Off Pond Culvert Repair (Cont.)


* Any omissions in this section are entirely unintentional.

2/6 John Bower

2/7 Phil Haussy

2/8 Gerod Briggs

2/9 Chris Hankins

2/10 Doc Holliday

2/12 Kirbee Monk

2/15 John Uebinger

2/18 Scott Stewart

2/20 Nick Gipson

Upcoming Events February Birthdays

1/26 Focus On Safety Breakfast

1/30 Speedy’s Retirement Party

2/9 Safety Committee Meeting

2/14 Valentine’s Day

2/16 Blood Drive

Wellness Corner

Zero In On Safety!

A good night’s sleep is vital to our physical health and emotional well-being. That’s why the benefits of good sleep should nev-er be underestimated and why getting a proper rest on a regular basis isn’t just a good idea, it’s an essential one. And to prove it, we’ve put together the top 10 reasons why a better sleep means a better you. 1. Sleep helps reduce stress If your body doesn’t get enough sleep, it can react by producing an elevated level of stress hormones, which are a natural re-sult of today’s faster paced lifestyles. Deep and regular sleep can help prevent this. 2. Sleep can improve your memory Ever noticed that when you’re really tired it’s harder to remember things? Basically this is your brain telling you that it’s not getting enough sleep. When you sleep well, your body may be resting but your brain is busy organizing and storing memories. So getting more quality sleep will help you remember and process things better. 3. Sleep can lower your blood pressure Higher blood pressure increases your chances of heart attacks and strokes, but getting plenty of restful sleep encourages a constant state of relaxation that can help reduce blood pressure and generally keep it under control. 4. Sleep helps your body to fight back While you’re sleeping your body is producing extra protein molecules that can strengthen your ability to fight infection. So if you’re feeling a bit run down and you don’t want it to turn into a full-blown cold, go to bed early and get lots of rest. 5. Sleep can help you maintain your weight Unfortunately, sleep won’t directly make you lose weight, but it can help you keep it under control by regulating the hormones that affect your appetite and reducing your cravings for high calorie foods.

6. Sleep puts you in a better mood

Lack of sleep can make us more agitated, so we’re more likely to snap at the boss or be grumpy with a loved one, neither of which is a good thing. The better you sleep the better your ability to stay, calm, controlled and reasonable. 7. Sleep could reduce your chances of diabetes Some research studies have shown that not getting enough sleep may lead to type 2 diabetes by affecting how your body pro-cesses glucose. It’s not conclusive by any means, but it’s yet another indication of how important the benefits of sleep can be. 8. Sleep helps keep your heart healthy A regular sleep pattern can help to lower the levels of stress and inflammation to your cardiovascular system, which in turn can reduce your chances of a stroke or heart condition. 9. Sleep can be a painkiller If you’re suffering pain from a recent injury like a sprained ankle, getting plenty of sleep can actually make you hurt less. Many studies have shown a link between sleep loss and a lower pain threshold. Basically the more sleep you get the less pain you might be in. 10. Sleep can make you smarter Along with a great night’s sleep, grabbing a quick nap in the daytime can contribute towards making your brain more effective and productive. You won’t necessarily be answering all the questions on University Challenge, but you may well feel sharper, more attentive and focused throughout the day. If you’ve ever thought that sleep doesn’t really matter all that much, think again, because it actually matters a great deal.

your electrical connection - newton power station retirees · examples include conducting...

Documents