/ 55_GS_3323_00
October 07, 2014
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USGCGulfstreamProgram
The Dow Chemical Company

GulfstreamGrating Inspection Requirements

Introduction / This policy aligns with the Global Elevated Work Standard requirement to have a management system in place for the Gulfstreamconstruction sites as required per Global Elevated Work Standard.
As part of this process, each construction site will manage their own grating inspections for their areas. Each construction site should have trained, qualified inspectors identified for their areas to perform grating inspections. This document will define the roles and requirements for grating inspections on the Gulfstream construction sites.
Policy / The following policy has been developed for Gulfstream:
  • Each construction site will use their resources (designated field staff) for inspections, release of grating decks for use, and minor repairs (replacing clips, tightening clips, etc.) until the project has been turned over to operations.
  • Inspections, including painting grating clips, will be completed when project grating installation is complete for an area while the life critical guards are still in placebefore turning over an area for entry without life critical guards and fall protection.
  • Inspections will be performed for previously completedand released grating that has been removed upon re-installation.

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Rolesand Responsibilities / Following are the roles and their responsibilities:
Roles / Responsibilities
Facility Grating Focal Point / This role is responsible for training new focal points and grating inspectors for aconstruction site. This role will be filled by the Construction Safety Leader or designee.
This role will be documented in the GulfstreamDelegation of Authority document.
This role must complete Grating Inspection (CP 8125) training or equivalent.
This role will ensure emissions are authorized with the construction EH&S Specialist for the usage of aerosol cans in accordance with PBR or MSS permit requirements prior to the start of work if applicable.
This role will ensure the Grating Inspector has completed required training.
Grating Subject Matter Expert (SME) / Dow designated construction representative familiar with Dowgrating installation and inspection requirements who provides direction to the contractor during installation.
Grating Inspector / Competent person, Dow or Contractor, responsible for grating survey, inspection and minor repairs as needed (replacing grating clips, etc.). Has completed required training (CP 8125)or equivalent.
Grating Repair Resources / Contractor qualified to perform grating repair. Also qualified to perform grating inspections.
Construction Managers / Ensure process is followed for their projects. Identifies Facility Grating Focal Point(s) for their projects.
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Grating Policy for Gulfstream, Continued

General Requirements / The following requirements shall be implemented for each construction site:
  1. Each project will designate and train a Grating Focal Point with responsibilities as described above.
  2. Each project will identify a Grating Subject Matter Expert who is familiar with Dow’s grating installation requirements.
  3. Each project will apply the grating inspection process, and complete and document the grating inspection checklist.
  4. The project must be divided into sections that can be easily segmented and identified (i.e. structure levels, small process areas, etc.). The inspection of a section shall be completed during one inspection task using one grating checklist per section (i.e. reactor area, catalyst area) by a qualified grating inspector.
  5. The project grating focal point should assist the qualified grating inspector in segmenting the facility prior to inspections beginning and must address any deficiencies that may need barricading or Life Critical Guarding.
  6. Each area within a projectwill have amanagement system in place to schedule and track the inspections.
  7. Each clipwill be painted with a spot of paint at time of inspection
  8. Authorization with the construction EH&S Specialist for usage of aerosol cans in accordance with PBR or MSS permit requirements or other air authorizations must be confirmed with the Facility FP prior to the start of work.
  9. Enamel based spray paint should be used. Both Krylon and Rust-Oleum would be acceptable brands.
  10. When a new piece of grating is installed, it should be painted with the current color of paint that is being used for inspectionsonce it has passed the grating inspection. This will also apply to grating that has been disturbed (removed, then replaced) and or repaired.
  11. The paint color shall be consistent across with the Dow site for 3 year inspections. A different color shall be used on each subsequent 3-year inspection. If a clip can`t pass inspection, it shall not be marked with the new inspection color. See table below.
  12. Orange paint shall only be used to indicate needed repairs. Do not use orange paint to indicate passing inspections.
  13. If grating that has been inspected and approved for use must be loosened to install pipe or equipment,the grating inspection process must be repeated for the piece that was loosened.

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Grating Policy for Gulfstream, Continued

Inspection Colors / The following table shows the colors to be used over the next 12 year cycle.
Year / Inspection Color
2010 - 2012 / Blue
2013 - 2015 / Green
2016 - 2018 / Black
2019 / Repeat cycle – Blue
*Repair Only / Orange
Related Documents / Refer to the following documents for additional information:
  • 21_GS_3001 Working at Heights (Global Elevated Work Standard)
  • Appendix A – Elevated Work Platform Checklist
  • Appendix B – Grating Inspection Checklist

Revision history / The following information documents at least the last 3 changes to this document, with all the changes listed for the last 6 months.
Date / Revised By / Changes
5/28/2014 / Mary Schwartz / Created policy for Gulfstream.
10/7/2014 / Mary Schwartz / Updated format and compressed pictures.

Appendix A

GulfstreamElevated Work Platform Inspection Checklist – Page 1

(For occupancy without fall protection on Permanent Platforms)

Inspectors:
CWP: / Structure: / Elevation:
Date: / Time:
Step / Action / Yes / No / N/A
1 / Access to elevated work platform:
a)Steps secured and evenly spaced
b)Complete handrails at adequate heights and tightly secured (Top rail = 42” high, midrail = 21” high, toe plate = 4” high)
c)Fixed ladders secured and provide safe access
d)Double arm gates in place at every fixed ladder landing
e)Ladder cage extensions in place from base of cage to top rail of platform
2 / Grating on elevated work platform:
a)LCG barricade installed where grating has been removed
b)Warning signs/LCG tags in place where LCG barricades are being used. All LCGs must be documented in the construction site spreadsheet.
c)For completed grating to be released for use, grating inspection checklist has been completed. (See Appendix B)
3 / Temporary hole covers:
a)Adequate materials being used for temporary hole covers ( ¾” plywood or greater)
b)Temporary hole covers secured to prevent displacement (bolted down)
c)Temporary hole covers labeled properly
d)Wooden hole covers protected with life critical guards/tags

GulfstreamElevated Work Platform Inspection Checklist – Page 2

Step / Action / Yes / No / N/A
4 / Permanent guardrail system around the elevated platform
a)Permanent guardrails are correct height (Top rail = 42” high, midrail = 21” high, toe plate = 4” high)
b)Permanent guardrails are secured
c)Adequate protection systems installed where permanent guardrail is incomplete on accessible and inaccessible structures (hard barricade, barricade tape with LCG, etc.)
d)Warning signs in place where permanent guardrails are incompleteon inaccessible structures.
5 / Permits
a)Grating removal permit has been completed where required
b)Life critical guard in place where required. All LCGs must be documented in the construction site spreadsheet.
c)Inspector/QC has verified grating meets specs per Engineering
d)Grating clips painted per inspection process
6 / Requirement / Location / Corrective Action / Initials / Date

Appendix B – Gulfstream Grating Inspection Checklist

GRATING INSPECTION CHECKLIST
Plant / Site Location: / Date:
Section Location ID:
Inspected By (Print ):
Instructions: For each item indicate, Yes (ok) - Needs Repair – N/A (for not applicable). Document any deficiencies at the bottom of the form. No more than one area should be assessed per checklist.
1. Metal Platform Grating / Ok / Needs
Repair / N/A
a. Grating is flat and corners or edges do not stick up more than 0.5 inches?
b. Grating does not move up or down and does not appear to be loose?
Tie down clips in place and tight against support?
NOTE: Recommended tightness of clip: Using a T-handle or wrench type tool, tighten fastener hand snug tight, ensuring that the grating near the fastener is in contact with the support below. The clip should be tight enough to prevent sliding of the grating.
Every piece of grating restrained at each corner by hold-down clips?

Every piece of grating should be restrained by at least two hold-down clips at each intermediate support.

No grating clip is used to hold two adjacent panels together.

Saddle clips should be used in place of standard (i.e. “Grate Fast”) clips on grating edges that are supported by channels with flanges extended outwards.

Is grating free from heavy corrosion or rust?

If grating is fastened with welds instead of clips, are all welds secure and located on each corner and two per each intermediate support, as a minimum? Note: Welds must be to support not adjacent grating.

c. Do large cutouts (> 18” diameter) have a support under the grating near the cutout, or is it banded?
d. Do the grating bars run parallel to the span (perpendicular to the supports)?

e. Do the grating metal bars overlap the supports (bear on the supports) by a minimum of 1”?
f. Is grating free of surface hazards and does it provide a solid, smooth walking surface (no up and down movement or trip hazards at grating joints)?
g. Is the grating free of holes that are large enough that a person could step into?
h. Are step supports free of rust or corrosion where steps meet the stair stringer (channel iron) on a flight of stairs?

2. Support Systems / Yes / No / N/A
a. Is grating adequately supported, e.g.
Supports below grating in good condition?
Supports around large equipment cutouts?
b. Are grating supports free of rust or corrosion?

c. For hinged panels, are there supports underneath that will support the panel in case the hinge fails?
3. Trench Grating / Yes / No / N/A
a. Is grating adequately supported, e.g.
Does the grating metal bars overlap the supports by a minimum of 1 ½”?
Is there a MAXIMUM of ¼” clearance from the grating to the support all the way around?

b. Grating does not move up or down and does not appear to be loose?
c. Grating is flat and corners or edges do not stick up more than 0.5 inches?
Example:
d. Do the grating bars run parallel to the span (perpendicular to the supports)?
e. Is the grating free of holes that are large enough that a person could step into?
4. Fiberglass Reinforced Plastic (FRP) Platform Grating / Yes No / N/A
a. Grating does not move up or down and does not appear to be loose?
Tie down clips in place and tight?
NOTE: Recommended tightness of clip: Using a T-handle or wrench type tool, tighten fastener hand snug tight, ensuring that the grating near the fastener is in contact with the support below. The clip should be tight enough to prevent sliding of the grating.
Every piece of grating restrained by at least four (4) corner hold-down clips?
Every piece of grating restrained by at least two (2) hold-down clips at each intermediate support?
No grating clip is used to hold two adjacent panels together.
Saddle clips should be used in place of standard (i.e. G-clips) clips on grating edges that are supported by channels with flanges extended outwards.
c. Is grating free of surface hazards and does it provide a solid, smooth walking surface (no up and down movement or trip hazards at grating joints)?
d. Is the grating free of holes that are large enough that a person could step into?
CORRECTIVE ACTIONS
Requirement / Location / Corrective Action / Initials / Date
1b / Block 16: Cutout missing band on third level, north side of pump #3 on discharge line (~20 feet from the staircase north side of structure) / JB / 1/1/08

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