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RELATED CLASSIFICATIONS Boiler Inspection and maintenance Box manufacturing - Corrugated Box manufacturing - Paperboard Crane services Logging Trucking - long haul Warehousing SPECIAL EXPOSURES Black liquor recovery boilers Difficulty of obtain parts and service for machines Highly flammable raw materials Long distance hauling of heavy loads Toxic wastes RISK DESCRIPTION Paper mills primarily are involved in manufacturing different types of paper from wood pulp and other fiber pulp. The end products vary widely and include bond paper, book and magazine paper, cleansing and facial tissue, wallpaper, newsprint, wrapping paper, milk containers, bags, corrugated containers, and cartons. Although the conversion of paper into these end products can occur at the mill site, the mill process usually ends with the winding, slitting, and coating of paper. Rolled and sheet paper then are shipped to converting or processing plants located nearer the marketplace. Most large companies have their own pulping operations, which may or may not be on the same premises as the paper mill. Paper mills generally are situated near major natural sources of wood. Mixed hardwood - softwood forest are located in the eastern United States, softwood forest on the west coast, and pine forest in the southern states. Most paper mills are concentrated in these regions, generally in remote, rural areas. Large paper mills usually possess independent electric power, steam, and water facilities. Many generate their own steam and electricity by using a mix of biomass (bark, branches, sawdust, and chips salvaged from forestry operations) and coal. Frequently they also will possess fire - fighting capabilities because of the significant fire and explosion potential of black liquor recovery boilers, high speed paper machines, and automated process control systems. Paper manufacturing has been a mature industry for several decades, and one which shows a trend of paralleling overall economic growth. A 1988 survey showed strong growth in most areas of the industry for 1987, especially that of white papers, due to the increased use of office copiers and computers as well as the popularity of quick print shops. However, other types of paper are being displaced by newer materials. Kraft paper manufacturing (the industry term for brown paper bags) in particular has lost ground to plastic bags. The electronics revolution, in the form of electronic fund transfers, electronic mail, an electronic data bases also has reduced the need for paper documentation to some extent. In order to counterbalance these trends, the paper industry currently is developing new products, such as aseptic food packaging, which eliminates the need for refrigeration, mew plastic / paper packaging combinations, retornable packaging and ovenable and microwavable paperboard. MATERIALS AND EQUIPMENT Logs and wood chips, furnish, cotton, rags and linen. Fourdrinier or cylinder paper machines, pulp digesters, debarkers, chippers, refiners, rotary screens, dryers, calenders, reels, winders, embossers, automatic finishing machines , slitters, sheet cutters, coaters, pumps, motors, rewinders, roll wrappers, rag willows, dusters, cutters. Bleaching agents, digester solutions, dyes, size, starches, resins, and various coating materials. High - pressure steam boilers, including black liquor recovery boilers, turbines, generators, transformers, miscellaneous electrical apparatus. Forklifts, cranes, clamp trucks, and hoists. Clarifiers, activated sludge treatment systems, gas control systems, electrostatic precipitators, and other waste treatment systems. Fire extinguishers and hydrants, hidropneumatic pumps, and other fire - fighting equipment. Delivery trucks and vans. Office machinery and equipment. PROCESS OR SERVICE Paper manufacturing begins with the delivery of the logs to the mill, either by company trucks, barge, or rail. In the woodyard, or log storage area, the logs are unloaded onto a log flume, which channels them into a drum debarker for bark removal. The debarked logs enter a chipper, a large rotating disc fitted with a series of knife blades which reduce the logs to chips about one - quarter of an inch thick. The chips then are transferred by conveyor belts to the chip pile for storage or to a chip bin for transfer to the digester. The digester, essentially a large vat, cooks the chips for several hours in a solution of sodium sulfide, sodium carbonate and sodium hydroxide, which helps dissolve the lignin binding the fibers together. The pulp then is washed to remove the chemicals and other impurities and sent to disk refiners or beaters. These machines loosen the elements binding together the fiber walls, which will allow the individual fibers to be bonded together into a sheet of paper. At this point several things also are added to the pulp: dyes, "size" (to fill the pores in the paper and improve water vapor resistance and surface printability), starches (to impart firmness and "rattle" to the paper), and resins (to give the paper water resistant properties). Other coating or additives, such as cotton, linen, or rags, may be necessary to create a specific type of paper. Pulp at this stage of the process is called furnish and is a mixture of 1% pulp fibers and 99% water. (Mills that do not maintain their own pulping operations begin the process at this point with the delivery of furnish.) Furnish is formed into the finished roll by the fourdrinier machine, which systematically drains off the water from the mixture and shapes the paper into the finished sheet. The mixture of fibers suspended in water first is pumped into the head box of the machine, trough a small opening at a high rate of speed onto a moving plastic screen of a very fine mesh, called a Fourdrinier wire. The water begins to drain immediately from the wire. Constant side - to - side vibration of the screen forces the fibers to bind to one another. Gravity is assisted on some machines by a built - in "shake" which not only helps the drainage of water but weaves the fiber together in a more uniform alignment. Table rolls and hydrafoils under the plastic screen support the wire and carry off additional water. As the sheet of paper forms, vacuum boxes remove the excess water by drawing the moisture from above the moving fiber mat. At this juncture, the mat also comes into contact with a dandy roll which rotates on top of the wire . The dandy, a wire - covered cylinder, applies pressure to the web, further serving to improve the formation of the fibers. Because the web still contains a high percentage of water when it makes contact with the dandy, a permanent impression, aptly called a water - mark, can be made in the fiber formation by means of a raised design in the dandy�s wire covering. The web continues its journey through a series of press rolls and felt blankets, which remove more water, and then is transferred onto a canvas - like dryer blanket. This brings the web into contact with steam - heated cylinders called dryer rolls, which absorb more moisture from the underside. If surface sizing is to take place, it occurs at this point. The size press is located in the dryer section of the machine and as the paper passes though this press, the surface size is administered to the sheet. Near the end of the process, when the sheet holds a remaining moisture content of about 6%, the web may be passed between metal rolls - a process called machine calendering. This process provides a smooth finish by ironing the sheets between heavy, polished rollers. The degree of pressure applied varies from light to heavy, depending on the desired smoothness of the finished sheet. Other types of paper may go through different processes that apply surface coatings such as clay to provide a smooth printing surface. The paper then is reeled into a full - width roll. Supercalendering, a separate off - machine process, consist of passing the paper through a number of calender rolls under great pressure to impart additional characteristics to the sheet such as increased smoothness and higher gloss. Supercalenders used for uncoated paper usually are composed of alternating chilled cast - iron rolls and paper rolls. A trip through the rewinder slits the paper into desired widths before a final rewinding into rolls of desired diameter and uniform density. Inn the course of slitting and rewinding, the paper also is checked for quality. Substandard sections are removed. The rolls then are removed to a warehouse for storage and shipping. As the pulp gradually is transformed into paper, the solution in which it was cooked undergoes a different process. The solution now is called black liquor, having darkened considerably during pulp digestion. Black liquor is very valuable to the paper mill because it contains both reusable chemicals and heat value, which are converted to usable substances by the black liquor recovery boiler. The energy generated by these boilers supplies 40% of the industry total energy needs. To make the liquor - know as "weak" black liquor because of its high water content - suitable for firing, it first is drained off fourdrinier machine. It passes through a series of steam - heated evaporators until in attains a solids content of 45 - 50 %. Then a "concentrator" utilizes the heat of the boiler flue gas to further raise the concentration to 65% or 70%. The "strong" black liquor now enters a mixing tank where sodium sulfate is added to replace the chemicals lost in the system. It is heated to lower its viscosity and pumped to the recovery furnace spray nozzles. The purpose of the recovery units is to reduce the sodium sulfate to sodium sulfide. As the liquor goes though each stage of the recovery cycle, it becomes extremely concentrated. The liquor is sprayed into the furnace where its organic ingredients are dehydrated and burned. Simultaneously, inorganic constituents, which have been separated from the organic ones, form a smelt bed on the furnace floor. At this stage black liquor recovery boilers become extremely dangerous, because of the high temperatures involved. If large quantities of water come into contact with the much hotter black liquor, the result is a violent thermodynamic explosion. Next, the smelt flows though water - cooled smelt spouts into a dissolving tank where it is mixed safely with water. This stage is called "green liquor". The green liquor undergoes a causticizing treatment using slaked lime to convert the sodium carbonate in the mixture to sodium hydroxide. After this treatment, the liquor is called "white liquor" and is ready to be used again as the cooking agent in the digester. AUTOMOBILE LIABILITY The insured probably will maintain a fleet of large, heavy trucks for transporting logs to the mill and/or delivering the finished rolls of paper to converting plants. The size of both the vehicles and their loads presents special safety problems. Paper mills frequently are situated in rural areas. Therefore, road conditions are an important hazard to consider. Are the roads wide enough for safe travel? Do they have any sharp turns or steep grades? The underwriter should investigate the condition of the roads and the arrangements for the removal of snow and ice. The weight and instability of the load may create a severe property damage exposure, especially if loads exceed the weight - bearing capacity of highways and bridges. Has the insured checked with the necessary public authorities before determining truck routes? How is the load stacked and secured? All wrapper chains should be fastened tightly. Insufficient safety measures may allow the cargo to shift and may cause the truck to overturn. Drivers may be required to haul the logs or paper over long distances in order to arrive at the distribution point. Do truckers travel with relief drivers? Excessive fatigue may lead to poor driving judgment and severe accidents. Is any backhaulig done? Determine the radius of operations and the frequency of delivery. Obtain MVRs on all know drivers . what are the drivers ages and experience? Drivers who are trained specifically in hauling heavy, unwieldy, or dangerous loads are a positive underwriting sing. What is the condition of the vehicles? They should be inspected and maintained regularly The condition of the brakes, tires and fuel and electrical systems is of prime importance. The insured also may own some like trucks or vans for evacuation purposes, employee mass transportation, and for conveying tools and supplies. Automobiles may be provided for salespeople and executives. Determine the amount of travelling done and the number of people using such vehicles. Do salespeople ever use personal cars for business? Check certificates of insurance. What is the altitude of management towards the implementation of safety measures? Are safety meetings ever held? See also Automobile Physical Damage. Automobile Physical Damage As discussed in Automobile Liability, the unstable loads and rough terrain greatly increase the possibility of accidents. The condition of the vehicles, the experience of the drivers, and the adequacy of preventive safety measures are extremely important in minimizing this exposure. If possible, assess the condition of frequently travellled roads. What kinds of safeguards do trucks have? Because of the extreme flammability of the load, the fuel tank should be of all - welded construction and located so as to reduce the possibility of mechanical damage, and thus fuel leakage and fires. Guides or baffles should be used to divert fuel spillage away from the cargo as well as from electrical and exhaust systems. Are trucks equipped with fire extinguishers? How well is the load secured? Loose logs or rolls of paper may shift and cause the driver to lose control and overturn the truck. The chains used to secure the load should be continuous from end to end. Where are trucks garaged? If they are kept in or near the paper storage facilities, hot exhaust or motor parts may ignite rolls of paper. The resulting fire may cause severe damage to the vehicles. Smaller trucks and automobiles owned by the insured and driven by salespeople or other employees may be damaged in traffic accidents. GENERAL LIABILITY The General Liability exposure is moderate. Salespersons, distributors, delivery and repair persons will have the motor contact with the mill. These people should be adequately supervised and their involvement with mill activities should be limited to the functions they perform. To avoid injury claims, their duties at the mill should be strictly delineated. A few companies may allow business groups or clients to tour the mill, but most do not. Visitors should be well - supervised and kept away from heavy production areas, if possible. Are tour groups warned to keep away from machinery? Are the y required to wear safety hats and glasses while in the work areas? Such groups also should be alerted to the possibility of encountering trucks, forklifts and cranes in their paths. Aisles should be clearly marked to indicate the routes of such vehicles. Are aisles or other heavy - traffic areas kept clean and free of debris? Equipment operators should be properly trained. Hoist, cranes, and forklifts moving rolls of paper must never swing loads above visitors heads. Fire spread to adjacent lands, which often are non owned forest, may cause severe losses. What is the quality of the fire - fighting systems in the mill? What provisions has the insured may for containing fires? ENVIRONMENTAL IMPAIRMENT LIABILITY Paper mills produce huge amounts of wastewater in the course of operations such as pulp digestion, screening and bleaching, and chemical recovery. In recent years, the industry has reduced the amount of water used in various processes, enabling it to use 60% less water for every ton of paper than it did in 1959. However, control of waste still is essential. Accidental or excessive discharge of chemicals may contaminate groundwater and other water sources. It also can deplete dissolved oxygen in ponds and streams, killing fish and other aquatic life. The Environmental Protection Agency (EPA) currently regulates a number of chemicals used in the papermaking process. These including zinc, pentachlorophenol, polychlorinated, biphenyl�s, trichlorophenol, and benzidines. What are the insured�s methods for disposing of these waste chemicals? EPA guidelines recommend either aerated stabilization basins or ponds and activated sludge treatment systems as the most cost - effective means of meeting effluent standards. The underwriter should thoroughly familiarize himself or herself with the EPA effluent limitation standards for paper mills, EPA 40 CFR parts 430 and 431. Disposal of wastewater pollutants usually is in the form of solid wastes and liquid concentrates, which may be deposited at land - fills. Has the landfill site been chosen carefully? Landfills should be on level ground to prevent horizontal or vertical migration of wastes to ground or surface waters. Careful documentation of all waste deposited at the landfill is essential. Should the EPA order cleanup of the landfill and attempt to assess companies using it, the insured may be able to avoid fines if the company can verify the nature of the waste it dumped. What precautions are taken to prevent large - scale spills in cooking liquor preparation areas, evaporation and recovery systems, and other areas of the plant? Strict housekeeping and water use practices, such as minimizing the intake of water by re - use and recirculation of waste waters, reduce the likelihood of accidents. Regular evaluations of suspended solids and dissolved organics in effluents also aid the pollution control process. The insured should keep records of such evaluations and the underwriter should obtain a copy. Is pollution - control equipment inspected regularly for sings of malfunctioning? Improper operation allows materials to be discharged rather than being settled and removed with the sludge. Solid always should be removed from the final effluent through the clarifier. The underwriter should obtain copies of the isured�s previous EPA inspection reports. Boilers discharge substantial quantities of sulfur dioxide gas. The use of wood residue fuels and low sulfur coal and oil, which emit very little sulfur dioxide, is desirable. Energy conservation and boiler upgrading also reduce the hazard. The sulfites used in the bleaching process may emit very unpleasant fumes and can spread to surrounding communities. Does the insured have and efficient gas control system? Have any complaints been filed by occupants of adjacent properties? Modern electrostatic precipitators should be able to remove 99% of industry air pollutants. Energy conservation and periodic boiler upgrading also may help reduce fumes. PRODUCT LIABILITY AND COMPLETED OPERATIONS Product liability suits against paper manufacturers are rare but possible. In most cases the paper product failed to perform to its specifications, thereby causing injury or property damage. Are quality control checks performed regularly? Are final inspections of the product conducted? Occasionally consumers have brought suit against a manufacturer because of the allergic reactions to chemicals in the paper. Is the paper treated with any special coatings? What paints and dyes does the insured use? In late 1987, the Environmental Protection Agency released the results of its National Dioxin Study. Its report indicated that pulp used for a wide range of paper products contains low levels of dioxin, and experimental human carcinogen. The products most suspect are those made wholly or partially from bleached kraft pulp, including paper towels, napkins, diapers, and toilet paper. Although the Environmental Protection Agency has stated that be projected levels of dioxin probably are too low affect public health, this may be a source of claims in the future. A technical report on the paper industry will be published by the end of 1988. BOILER AND MACHINERY The exposure here may be very severe. Although large - scale accidents are not frequent, when they do occur they may cause losses in the millions of dollars. The most important factors in reducing the severity of the exposure are thorough employee training, the use of automatic safety controls, and regular inspection and maintenance of parts and internal (water side) surface. All machine operators and other employees working in the vicinity must be fully familiar with the components of their equipment, including safety controls. They should be knowledgeable enough about emergency procedures to react instantly when the situation demands it. Many equipment manufactures offer operator training programs and manuals with specific recommendations and safety procedures. Does the insured take advantage of this type of information? Are drills ever held to simulate accidents? Although such exercises do sharpen skills and improved reaction time, discretion must be used because some drills themselves can cause substantial damage. Do employees receive supplemental or refresher training courses in the safe operation or equipment? Operators of a fourdrinier machine should test periodically for leakage, steam pressure, speed, temperature, lubrication of bearings, gear alignment, and abnormal noise of vibration. Mechanical monitors should be used where appropriate and should be maintained in good working order. Are safety valves tested top ensure they will function adequately at the correct pressure? Internal surfaces should be inspected semiannually for sings of cracking, corrosion, erosion and looseness of internal parts. These conditions may have a number of causes, including improper maintenance , excessive operating pressure or speed, and vibration. Paper dryers should be controlled carefully during startup to avoid stress on parts due to temperature swings in the machine. Necessary resurfacing of the exterior shell thickness and maximum allowable operating pressure should be kept. Condensates should be monitored to avoid buildup and stress on the machine. Again, periodic checks for defects such as cracks, thinning and corrosion are vital to preventing accidents. An manual inspection of internal and external surfaces should include the center shaft, syphons, and condensate removal equipment. Do employees observe the manufacturer�s operating instructions? Are exposed surfaces cleaned regularly? Steam turbines are subject to frequent blades failures. Usually due to steam impurities (particles suspended in the steam, such as silica, sodium and chloride). They also can build up in the tubing forming deposits called scale. Scale blocks the water flowing through the tubing, diminishing the water�s cooling effect. Eventually this causes cracking and corrosion of the turbine casing, which in turn produce overheating and breakdown An on - site water treatment system and a program of regular inspections to maintain steam purity will greatly reduce the severity of these problems. Are generators and transformers serviced regularly? Are loose connections, fraying wires, and aging parts replaced promptly? WORKERS� COMPENSATION Machinery hazards present the greatest exposure in this line. Injuries may range from minor cuts and burns to back strains, hernias crushed or amputated limbs, and death. A number of safeguards exist to prevent or reduce the severity of such injuries. In general, materials handing should be mechanized as much as possible to cut down on direct manual contact. Automatic feed systems for machines such as winders and calenders are recommended. Where they are no feasible, safety guards with drive mechanism interlocks must be used, especially at power transmission points. Do guards meet or exceed state and federal codes? Does management insist that guards be replaced immediately when removed for maintenance? Are color codes used to identify dangerous parts of machinery and emergency stop bars? Guillotine type cutters should be designed to prevent "repeat" action of the cutting blade and to require two - handed operation. Power baling presses should have guard rails around the hopper opening and the start switches should be guarded against accidental contact. Do conveyor belts have cable stop or buttons? Do workers know how to use these safety devices? Are all employees fully trained in the safe use and operation of equipment? The insured should have a procedural a accountability program to ensure that power is locked out during repairs or at the beginning of a shift as workers prepare machinery. Plant industrial equipment should have clearly visible warning lights, especially when operated in areas with high background noise or when electrical equipment is being used. Hoist and cranes should have safe hook - up mechanism for their loads. Are equipment operators thoroughly trained in the safe use and operation of their machinery? Do crane operators keep workers clear of raised loads? (see also Crane Services) Floors over which lift trucks operate should be clear of debris as well as uneven permanent obstacles such as raised drain grates. Inhalation of chemical and toxic gases such as chlorine and ammonia may cause inflammation of mucous membranes and respiratory aliments. Workers also may be exposed to dust from winder operations, especially if absorbent papers are manufactured, and to gases given off both in the pulp treatment process and in wastewater disposal. Are employees working in close proximity to these processes provided with air filter respirators, face masks and goggles? Localized ventilation systems and makeup air systems also reduce exposure to air - borne irritants. Methanol, a colorless liquid used in coating paper, poses serious health risk. Long - term inhalation of this substance may cause chronic poisoning; symptoms range from irritation of the mucous membranes to vertigo, clouded vision, vomiting and colic. Exposure to liquid methanol can cause dermatitis. In addition to the precautions mentioned above, working areas where methanol is handled should have local exhaust ventilation. Tanks and other places which have contained methanol should e thoroughly ventilated before workers enter. If this is not possible, workers entering such enclosures should be provided with airline respirators and rescue harnesses, and a helper should be stationed outside the enclosure in case of emergency. Are workers given regular medical checkups to detect any indications of poisoning? Handling cleaning compounds, solvents and epoxy, as well as the aforementioned chemicals, may result in dermatitis. Gloves, aprons, protective clothing of wool or cotton, and barrier creams are recommended. Converting line workers, materials equipment handlers, and cleaning personnel all engage in work requiring extreme bodily exertion. These workers handle, for example, large cases of products, huge rolls of paper, and roll shafts and cores. Are mechanical handling devices provided wherever possible? Are proper lifting procedures emphasized by management? Ergonomic considerations in designing job tasks and stations also help top reduce back injuries such as sprains and strains. Is the conveyor belt height designed to minimize the necessity of stressful movements? A corporate - sponsored exercise program for employees, emphasizing stretching and strengthening exercises for the back and legs, is a positive underwriting sign. Good housekeeping is essential. Areas where water can accumulate and/or form a slick surface, such as the sides of metal machines, should be provided with effective drainage or non - slip surfaces. Stairways, ladders and elevated walkways, including machine cat walks, also should have non slip surfaces if adjacent to wet areas, as well as guard rails to prevent falls. Are snow and ice removed promptly from outside walkways and parking lots? Areas that accumulate a great deal of pulp dust ideally should have dust collection systems. Absent that, floors should be swept several times a day to reduce the likelihood of respiratory problems. Work stations and task should be designed to minimize the required movements of workers in potentially slippery areas. Insureds located in rural areas may have a difficult time obtaining medical assistance in the event of an emergency. Does the insured have a fully equipped emergency hospital and are medical professionals, such as doctors or nurses, on the premises at all times? What are the evacuation procedures in the event of fire? Are these procedures posted near areas vulnerable to fire? Drills should be held on a regular basis. Are fire exist clearly marked and easily accessible? | |||||||||||||||||||||||
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CRIME The exposure generally is moderate, since large rolls of paper generally are not attractive to thieves. The danger is mostly to computers and to any cash or securities that may be kept on the premises. Does the insured have secure locks an all windows and doors? Is cash transferred to a bank or a safe at the end of the day? Because the insured may have a number of large accounts, there may be fidelity exposure. How many employees are responsible for balancing the company books? Are figures ever cross - checked by employees outside the accounting department? Are outside audits conducted regularly? Vandalism may be a problem if the factor is located in a high - crime or insolated area. INLAND MARINE This exposure generally is moderate. The insured may need Electronic Data Processing coverage for computer equipment. Accounts Receivable coverage also may be desirable. Are- duplicate sets of records kept at a separate location? Motor Truck Cargo insurance is needed if the insured transports the finished paper or the raw logs. How are these loads secured against damage? See Automobile Liability and Automobile Physical damage for further clarification. Does the insured use common carriers to transport the finished product? If so, the underwriter should determine the limits of liability. FIRE AND E.C. Paper mills contain wast amounts of combustible material, from wood, bark, and paper residues to flammable solvents used in bleaching and coating the finished product. To prevent large losses, the insured should have a well - organized fire - fighting plan. The mill should have its own water reservoir. Fire brigades also are desirable, especially in remote areas where outside fire protection may be inadequate or may be slow in reaching the site. Accordingly, the woodyard should be equipped with an alarm system to notify the brigade of any problems. Fire trucks may be necessary for large mills: Hydrant or nozzle stations are vital for paper machines, finishing and warehouse buildings, the pulp mill, and the wood storage and handing areas: Are fire extinguishers easily accessible? Black liquor recovery boilers constitute a major hazard. Firing with weak black liquor is extremely dangerous because of its high water content (see process). Water leaks that enter the furnace may cause huge explosions. Instruments that sound a warning alarm when the solids contents of the boiler drops below 58% and subsequently shut off or divert liquor from the furnace are absolutely essential. Maintenance of boiler parts also is vital. Corrosive chemicals can cause cracks and ruptures in boiler tubing, allowing water to escape. Internal inspections should be conducted on a semi - annual basis. Fireside surfaces should be checked during these inspections. The Black Liquor Recovery Boiler Advisory Committee, a committee composed of paper companies, boiler manufactures and insurance companies, has developed its own Emergency Shutdown Procedure. This procedure must be initiated whenever water in any amount has been detected in the furnace and cannot be stopped immediately, or when any water leak develops in a pressure part. These leaks may penetrate to the smelt bed and cause an explosion. Ate employees capable of executing these procedures? Does the insured post the steps involved at each recovery unit control station? Smoking should be strictly prohibited in all working areas, and should be permitted only in designated enclosures. Does the insured hold regular meetings to emphasize fire safety education? Does the insured have a good sprinkler system? The paper machine, which processes and dries large quantities of combustible material, should be well protected, especially the ducts, drying hood, oil lubrication system, and "dry end" of the machine, from which the finished paper emerges. Office enclosures, control rooms, as well as the basement underneath the paper dryer section, should have sprinkler protection as well. Stock and rack storage areas should have - in rack sprinklers. Hydropneumatic tanks and fire pumps also are important. Is the sprinkler system regularly maintained? Are valves and electrical components inspected periodically? The sprinkler system is vital both reducing fire spread and in limiting any resulting losses. What is the condition of the mill buildings? Each building should have adequate firewalls with a minimum one-hour, preferably two or four hour, fire rating. Are buildings equipped with adequate ventilation systems to prevent buildup of flammable vapors, smoke and heat? Does the design of each building provide clear access routes and walkways for firefighters? What is the extent and location of electrical power and control cables with combustible insulation? These cables usually are located in the powerhouse, pulp mill, paper machine building, and bellow the process control and computer rooms. Wall and floor openings around electrical cable trays or piping should be tightly sealed with noncombustible material. Defective lighting and electrical equipment are major causes of paper mill fires. Are wiring and lighting systems properly installed and maintained? Are they correctly grounded and provided with aver current protection? Machinery operations also pose hazards. Deposits of paper dust can collect on machinery. Walls and ceilings. When exposed to frictional heat, electrical defects, or flammable vapors or solvents, this dust can ignite rapidly. A dust collection systems, which eliminates the dust as it accumulates, is ideal. In the absence of such a system, water washdowns of machinery, except for steam - heated dryers, may help reduce the hazard. Large quantities of excess paper also may accumulate below the paper machine. Is this area cleaned on a regular basis? Static sparks produced by machine functions may ignite dust or paper. What steps are taken to reduce this hazard? The log piles in outdoor woodyards are highly susceptible to fire, particularly during dry periods. Poor housekeeping, dried - out wood refuse, and large, closely - stacked log piles increase the hazard. Welding and smoking should not be permitted in this area and any materials -handling equipment used in the vicinity should be well maintained. To decrease the possibility of fire spread, log piles should be kept small and well - separated. Roll paper storage fires cause some of the paper industry's most severe losses. Paper rolls "exfoliate", or peel off in this layers, during a fire, constantly exposing a fresh layer from which the fire can feed. Does the insured comply with the provisions of NFPA 231F, which is designed to reduce this hazard? For example, heavy - weight kraft wrappers and/or steel bands on both sides and ends of the rolls helps retard exfoliation. Tight nesting and vertical storage of paper rolls also slow down fire spread by restricting the air flow to the fire. Warehouses may have a very large clearance between the top of the stocks and the ceiling sprinklers, which diminishes sprinkler effectiveness and promotes rapid upward acceleration of hot fire gases. High - density sprinkler systems are recommended for this type of situation. Are the warehouses subdivided? Full fires stops are desirable in large warehouses to reduce the amount of stocks that would be exposed to a single fire. Any welding done in the mill presents a major hazard, especially in woodyard and preparation buildings, near the paper machine, and in the roll paper warehouse. Designated welding areas and supervision of all hot work is essential. The chemicals used in the bleaching process, especially chlorine dioxide and hypochlorites, are highly flammable. The latter also has a high explosion potential, especially upon contact with water. Other flammable substances used in the manufacturing process include methanol and chlorine. Are these chemicals stored in approved metal containers and cabinets? Does the insured provide localized ventilation in the areas where these gases are used? UNDERWRITER'S CHECK LIST Does the insured maintain a fleet of vehicles for transporting logs to the mill and finished product to converting plants? What is the condition of frequently travelled roads? How are loads secured? What type of driver training is provided? Are tours of the mill ever conducted? If so, is the tour supervised by a manager or responsible employee at all times? How does the insured dispose of toxic wastes? What steps are taken to prevent spills in the black liquor recovery boiler? Is pollution equipment inspected regularly for signs of wear and malfunctioning? Does the insured comply with EPA standards 40 CFR parts 430 and 431 regarding effluent discharge? Are employees provided with protective clothing, goggles, and mask when working around toxic or irritating chemicals? Are all machines equipped with safety guards? Are proper lifting procedures emphasized, especially where workers are lifting extremely heavy loads? Is the sprinkler system inspected and maintained on a regular basis? What steps are taken to prevent roll - paper storage fires? Are black liquor recovery boiler operators thoroughly trained in the safe operation of the unit? Do they understand correct emergency procedures? Are boiler parts inspected regularly for signs of corrosion and cracking? Does the boiler recovery system have instrumentation that alerts operators when the solids level drops bellow 58%? Does the insured rely on a single manufacturer or supplier for repair parts and service for machinery? | |||||||||||||||||||||||
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