Archive | Safety Systems / Training

499

3:20 pm
January 27, 2014
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Forward Observations: Calling Out the Man

By Rick Carter, Executive Editor

Except for one thing, William Marsh’s story is not so unusual. The owner of American Bar Products, a Pennsylvania-based maker of cold-finished steel bars, Marsh was fined $8000 by OSHA in 2011 for lockout/tagout deficiencies. Though reduced from $20,000, the fine was tough on his small company and a blow to Marsh’s pride. The fact that the investigation was triggered by a disgruntled employee’s false claims about company safety was also disturbing, and a foreshadowing of things to come.

When the same employee was fired in 2012 for cheating on his time card, Marsh warned his team to expect another visit from OSHA. “I thought it would take two weeks,” he said. “It took two days.” And here’s the twist: “This time I didn’t let them in. I said they needed a warrant, and that when they returned, to bring the area supervisor, and that my congressman and an agent of the press would be here.”

After that, nothing—until late last year when OSHA returned, unannounced, to check plant noise levels. “They were just in the neighborhood,” said Marsh, “but they had no formal complaint, so I denied their entry again. And they got a warrant, which listed ‘probable cause’ as their reason for entry.” When OSHA declined to explain the cause, Marsh decided to take his case to the world.

“I invited members of the local news media to tour our facility,” he said, “and they ran stories about what was going on.” He also invited two state senators, one of whom was quoted saying OSHA’s actions sounded like “an agency gone rogue.” But the officials could do nothing for Marsh, nor could the local-business owners who called and emailed their support after the articles appeared. When Marsh asked them to join him at a press conference he was planning, all politely declined.

Marsh held the conference anyway, in early December, the day before the warrant-authorized inspection was scheduled. Posted on YouTube (search “William Marsh standing up to OSHA”), the event shows a passionate company owner who believes in his ability to run his business properly and safely, with his experienced staff, without government intervention. When I spoke with Marsh on the day of the inspection, the agent had already found several instances of missing paperwork. Marsh was not encouraged. “I expect to be fined heavily,” he said, “probably $10,000 to $20,000 from OSHA, in addition to my legal fees. And my plant will be no safer for it.”

At press time, Marsh didn’t know the official outcome of the inspection. In our conversation, he stressed that while his shop’s heavy-industry environment is not pristine, “it is not unsafe. For what we do,” he said, “it is an exemplary manufacturing facility.” And I don’t doubt it. The unfortunate lesson here, however, is that government regulations have evolved to where they are because not every business owner is as capable or trustworthy as William Marsh may be.

With his David/Goliath approach and belief that his property was searched unreasonably, it’s hard to be totally critical of Marsh. Yet it’s harder still to watch him take another hit for something he could easily correct. His small operation may lack “the ability to finance a paperwork engine,” as he claimed, but if he wants to stay in business he will probably have to get that engine going. Better to bring on part-time office help than hand over big money in federal fines. As everyone else Marsh looked to for help seemed to already know, that’s a sure way to bring his story to a quick end. MT&AP

rcarter@atpnetwork.com

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375

1:58 pm
November 15, 2013
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Technology Showcase: Safety First

Are You Overlooking Some Common Safety Problems?

At least two seemingly benign hazards lurking around today’s operations could be just a damaging as arc flash. Do your maintenance teams have the knowledge and skills they need to deal with these concerns?

1113techshow1We are all familiar with potential hazards relating to arc flash and other electrical incidents. But what about other safety issues that plants and facilities face? Some common, yet often overlooked, safety issues include those relating to pressure and pressurized systems. These include boilers and their associated distribution systems and high-pressure refrigerants. While this is not a complete list, it’s worth noting that incidents involving these types of systems and products are just as important and potentially hazardous as any arc flash incident.

Boiler system concerns
Boiler accidents can result from faulty pressure-relief valves, low water levels or corrosion to metal components caused by improper water treatment.

  • If a pressure valve malfunctions because of corrosion or lack of testing and recertification, it can fail to open or relieve its designed capacity of steam or hot water. The pressures and temperatures in the boiler will then build above design specifications and a pressure-vessel failure will occur.
  • If the water level in the boiler drops and exposes the boiler tubes, overheating can occur and lead to further damage to the boiler—possibly causing it to explode.
  • Over time, without proper water treatment, water may become corrosive and scale may form on the heating surfaces, which in turn can cause damage to the structural integrity of the boiler itself.
  • Finally, improper maintenance may also cause pressure problems and is a common cause of boiler accidents.


High-pressure refrigerant concerns
Similar to boilers are issues concerning high-pressure refrigerants. One such refrigerant—R-410A—is of particular concern: Although it does not have the ozone-depleting effects of traditional refrigerants, R-410A operates at 40% to 70% higher pressures. That means operators must be exceedingly careful when working with systems that use this type of refrigerant.

  • A key consideration with R-410A is to verify that equipment for which you are using it is designed for this refrigerant. This will ensure that the equipment can handle the higher pressures that are encountered when working with R-410A.
  • Since most older systems weren’t designed to handle the types of higher pressures associated with R-410A, retrofitting them is not recommended.


Using proper equipment and proper and scheduled maintenance, facilities can avoid many of these accidents before they happen.
For more information on these and other workplace-safety issues, as well as related real-world plant, building and facility maintenance training programs, visit: americantrainco.com.

Full-Time, Advanced Arc-Flash Technology

According to GE, its ArcWatch technology offers full-time, automatic, always-on protection and reliability for people, property and equipment. It works through a combination of communication algorithms across the GE portfolio of circuit breakers by using instantaneous zone-selective interlocking (I-ZSI) and waveform recognition (WFR) to ensure that only circuit breakers nearest to the fault will trip, which happens in as little as four milliseconds. Systems embedded with this technology reduce the impact of an arc-flash event to <8 cal/cm2, translating into lower requirements for using personal protective equipment. ArcWatch-enabled circuit breaker families from GE include the EntelliGuard*, Record Plus* and Spectra RMS* series. Shown here, the recently launched PremEon* S trip unit used in conjunction with the Record Plus platform is an advanced electronic trip unit that provides higher levels of accuracy for selective ratings without compromising safety, especially during maintenance operations. It also eliminates rating plugs for jobsite simplicity and adjustability. Recently introduced EntelliGuard enhancements simplify in-the-field energy management and user interface with improved breaker-maintenance diagnostic information.

GE Industrial Solutions
Plainville, CT

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263

8:33 pm
April 24, 2013
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Technology Showcase: Safety Matters

Power Monitoring App For iPads Helps Facilitate Safe Operation In Hazardous Locations

Summit Technology, Inc., manufacturer of the PowerSight™ line of power monitors and power-quality analyzers, has introduced PSM-i (Powersight Manager software for the iPad®) as a free app download on Apple iTunes.

With PSM-i installed on an iPad, the user can set up, operate, display and analyze data graphically from a WiFi-enabled PowerSight meter that is often inaccessible without taking cumbersome safety precautions. For example, the NFPA 70E and CSA Z462 standards require the use of personal protective equipment, or PPE, when the circuits to be accessed present an arc flash hazard. While an iPad equipped with PSM-i does not eliminate the need for PPE entirely, it reduces PPE use to a minimum to provide relief to the worker operating under difficult conditions.

According to the company, the iPad’s small size and weight and outstanding graphics capabilities make it an ideal companion for testing with PowerSight meters. The “Wizard Screens” feature provides a simple and intuitive guide to planning and setting up a power study. In addition, the user can view dozens of high-resolution screens that allow real-time access to waveforms and phasor diagrams, as well as multi-meter displays of instantaneous power values. Among other things, an iPad equipped with PSM-i also enables the user to record and download monitoring data and then review, store
and/or email the results. The software incorporates a built-in Report Writer that compiles data in a just a few seconds and generates a professional-looking summary that includes text table and graph plots.

Summit Technology, Inc.
Walnut Creek, CA


EPA-Compliant Particulate Monitor

FilterSense’s PM 100 continuous particulate emission monitor and baghouse leak detector incorporates Automatic Zero and Span Checks to eliminate manual calibration audits as required by the US EPA for MACT and other regulations for fabric-filter particulate emissions monitoring. In addition to the product’s internal self-checks, the manufacturer says its field-proven induction-sensing and protected-probe technologies provide enhanced reliability over older opacity and triboelectic technologies. As particles flow near and around the probe, a minute current is induced. A DSP processes that signal into an absolute output relative to particulate flow. A protective layer over the probe works in combination with induction-sensing to ensure reliable operation with conductive particulate, moist powders, corrosive gases and particulate buildup. According to FilterSense, maintenance is minimal with this modular-platform product, and there’s no need for an air purge. For durability, the sensors are passive and free of electronics. For safe, easy access and to facilitate EPA QA checks, the control unit and electronics are remote.

FilterSense
Beverly, MA

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397

7:00 pm
October 11, 2011
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Electrical-Safety Sense: The Benefits Of PESDs

Permanent electrical safety devices (PESDs) have had a marked impact on electrical safety practices. Because they are mounted on the outside of the electrical enclosure, these devices directly affect Lock-out Tag-out (LOTO) procedures. Let’s review them with regard to Article 120.1 of the NFPA 70E.

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