T08 - Maintaining Your Safety Plan

Transcription

1 T08 - Maintaining Your Safety Plan PUBLIC INFORMATION Rev 5058-CO900E

2 2 Session Description Some of the strongest, most productive companies in the world rely on safety as a pillar for their successful business model. Once a safety plan is in place, maintenance of that plan is as critical as the plan itself. But what does a safety system validation entail? We will explain how you can help ensure proper safety system installation and functionality through validation, lockout tagout (LOTO), and arc flash assessment to help identify issues and simple improvements to help with risk reductions and overall LOTO time reduction.

3 3 Agenda I. Validation II. Arc Flash III. LOTO

4 4 Functional Safety Life Cycle STEP 5 MAINTAIN & IMPROVE SAFETY SYSTEM STEP 1 TEAM BASED RISK ASSESSMENT Safety Life Cycle STEP 4 SAFETY SYSTEM INSTALLATION & VALIDATION STEP 3 SAFETY SYSTEM DESIGN & VERIFICATION STEP 2 SAFETY SYSTEM FUNCTIONAL REQUIREMENTS

5 Program Verification And Validation Verification & Validation The standards require program verification & validation to ensure that the safety system operates as intended. Each safety function is evaluated to ensure proper operation. Safety projects are checked and safety signatures are created to protect program integrity.

6 Copyri Safety System Validation What is Needed Risk Assessment Documentation Safety Functional Spec: Guarding, Electrical, Pneumatic, Hydraulic, Environmental, Temperature, Pressure, Chemical, and related safety functions and requirements. Controls Spec / Design Control System and Communications Design

7 7 Why Do A Validation? Completing a Safety Validation ensures the safety system installed meets all design criteria as called for by the safety functional design specification (SFRS), assessment and most standards Performing Validations on a regular basis protects your safety investment which helps assure Machine Safety Compliance. Many standards, such as, ISO 14119, Safety of Machinery; ISO 13850, Safety of Machinery; ISO 10218, Robots and Robotic Devices and ANSI B11.19, Performance Criteria for Safeguarding, but not limited to, reference the need for regular verification of safety circuits keeping in you compliance with safety standards -

8 ANSI V&V Requirements part 6.8 Note ANSI B Safety of Machinery General Requirements & Risk Assessments

9 ANSI V&V Requirements part 7.2 Note SRP / CS Safety Related Portion of the Control System

10 10 When was the Last Time You... checked your Fire Extinguishers? checked your Emergency Alert System? checked your Emergency Medical Supplies? checked E-Stops? check your Cranes? verified your light curtain(s) work properly? verified your inter-lock(s) work properly? verified and validated that you safety system actually does what it is supposed to do?

11 Safety Checklists and Validation Safety Checklists There are a number of sample checklists that are located in the GuardLogix users manuals and on-line at AB.com to help users develop verification and validation checklists. These checklists guide you thru the evaluation process.

12 Sample Safety V&V Checklist for Safety Functions Safety V&V Plans help you document that the system operated as intended at installation. This provides a documentation trail and proof of due diligence.

13 13 Agenda I. Validation II. Arc Flash III. LOTO

14 14 Arc Flash The NFPA requires 3 phase panels above 50V to be labeled with an AF Hazard Boundary

15 15 Arc Flash Maintenance Program Arc Flash needs to be updated every 5 years Rockwell Automation offers the following maintenance package Site visit and facility inspection (annual) Facility power/utility analysis (annual) News and compliance updates (annual) Tracking of equipment changes/revisions (quarterly) Access to monthly on-line training sessions (unlimited) Engineering support (unlimited) Written safety policies that can be adopted at the facility or corporate wide (unlimited) Energized work permits for use on every live electrical job (unlimited)

16 16 Arc Flash Maintenance Program Training Training requirements needs are continuous and are dictated by both OSHA and NFPA 70E. The following employees require training during the year per these standards. a. New employees should be trained. b. Employees that are transferred and may come in contact with energized equipment should be trained. c. Employees that do not comply with the safety-related electrical work practices need to be retrained. d. Employees that have not worked on energized equipment for one year or more regardless if they were previously trained on energized equipment.

17 17 Question? What if Utility Company changes power to Utility Transformer? Do they need to tell you?

18 18 Agenda I. Validation II. Arc Flash III. LOTO

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20 Quick Review Lockout-Tagout Basics 1. LOTO = Controlling hazardous energy to protect workers during service of equipment. 2. Applying a lock and tag prevents inadvertent start-up and protects the worker who is servicing. 3. There are 5 components that OSHA requires (both federal and state): Machine Specific Procedures Employee Training Annual Auditing Corporate Policy Locks, Tags & Devices Copyright 2014 ESC Services, Inc. All Rights reserved.

21 Industry Best Practices Lockout-Tagout Components Addressed with Industry Best Practice

22 The best solutions available today Machine Specific Procedures Employee Training Annual Auditing Corporate Policy Locks, Tags & Devices Copyright 2014 ESC Services, Inc. All Rights reserved.

23 Machine Specific Procedures Employee Training Annual Auditing Corporate Policy Locks, Tags & Devices Then: Now: Now: Top 3 Benefits: o Up to 50% or more faster to follow o Easier to train authorized employees o Safer by encouraging usage Copyright 2014 ESC Services, Inc. All Rights reserved.

24 Machine Specific Procedures Employee Training Annual Auditing Corporate Policy Locks, Tags & Devices Then: Now: Top 3 Benefits: o o o Interactive training online Employee audits with tablets Central cloud location for real time training status \ o Training is quicker and less costly o Interactive training ensures comprehension o Higher quality hands on training with targeted input

25 Machine Specific Procedures Employee Training Annual Auditing Corporate Policy Locks, Tags & Devices Then: Now: Top 3 Benefits: o Audits are up to 85% more efficient o Higher quality data obtained o Data accessible in real time

26 Machine Specific Procedures Employee Training Annual Auditing Corporate Policy Locks, Tags & Devices Then: Now: Top 3 Benefits: o Easier to access o Instant updates and realtime controlled document o Reduces chance for OSHA fines

27 Machine Specific Procedures Employee Training Annual Auditing Corporate Policy Locks, Tags & Devices Then: Now: Top 3 Benefits: o Less expensive o Easy to identify for LOTO usage o Quick access with boards and kits

28 Graphical vs. Text Both procedures contain the same information Both are OSHA Compliant On a daily basis or an emergency - Which would you rather use?

29 OSHA Periodic Inspection Requirements (c)(6) (c)(6)(i) The employer shall conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirements of this standard are being followed (c)(6)(i)(A) The periodic inspection shall be performed by an authorized employee other than the ones(s) utilizing the energy control procedure being inspected (c)(6)(i)(B) The periodic inspection shall be conducted to correct any deviations or inadequacies identified (c)(6)(i)(C) Where lockout is used for energy control, the periodic inspection shall include a review, between the inspector and each authorized employee, of that employee's responsibilities under the energy control procedure being inspected (c)(6)(i)(D) Where tagout is used for energy control, the periodic inspection shall include a review, between the inspector and each authorized and affected employee, of that employee's responsibilities under the energy control procedure being inspected, and the elements set forth in paragraph (c)(7)(ii) of this section (c)(6)(ii) The employer shall certify that the periodic inspections have been performed. The certification shall identify the machine or equipment on which the energy control procedure was being utilized, the date of the inspection, the employees included in the inspection, and the person performing the inspection. PUBLIC INFORMATION 29

30 30 OSHA Employee Retraining (c)(7)(iii) (c)(7)(iii)(A) Retraining shall be provided for all authorized and affected employees whenever there is a change in their job assignments, a change in machines, equipment or processes that present a new hazard, or when there is a change in the energy control procedures (c)(7)(iii)(B) Additional retraining shall also be conducted whenever a periodic inspection under paragraph (c)(6) of this section reveals, or whenever the employer has reason to believe that there are deviations from or inadequacies in the employee's knowledge or use of the energy control procedures (c)(7)(iii)(C) The retraining shall reestablish employee proficiency and introduce new or revised control methods and procedures, as necessary (c)(7)(iv) The employer shall certify that employee training has been accomplished and is being kept up to date. The certification shall contain each employee's name and dates of training.

31 31 OSHA Training / Communication Requirements (c)(7) (c)(7)(i) (c)(7)(i)(A) (c)(7)(i)(B) (c)(7)(i)(C) The employer shall provide training to ensure that the purpose and function of the energy control program are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees. The training shall include the following: Each authorized employee shall receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control. Each affected employee shall be instructed in the purpose and use of the energy control procedure. All other employees whose work operations are or may be in an area where energy control procedures may be utilized, shall be instructed about the procedure, and about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out.

32 32 OSHA Training / Communication Requirements Cont d (c)(7)(ii) (c)(7)(ii)(A) (c)(7)(ii)(B) (c)(7)(ii)(C) (c)(7)(ii)(D) (c)(7)(ii)(E) (c)(7)(ii)(F) When tagout systems are used, employees shall also be trained in the following limitations of tags: Tags are essentially warning devices affixed to energy isolating devices, and do not provide the physical restraint on those devices that is provided by a lock. When a tag is attached to an energy isolating means, it is not to be removed without authorization of the authorized person responsible for it, and it is never to be bypassed, ignored, or otherwise defeated. Tags must be legible and understandable by all authorized employees, affected employees, and all other employees whose work operations are or may be in the area, in order to be effective. Tags and their means of attachment must be made of materials which will withstand the environmental conditions encountered in the workplace. Tags may evoke a false sense of security, and their meaning needs to be understood as part of the overall energy control program. Tags must be securely attached to energy isolating devices so that they cannot be inadvertently or accidentally detached during use.

33 The next evolution of lockout-tagout is here.

34 Modern Solutions for Lockout-Tagout

35 LOTO ScanESC Tracking Lockouts PUBLIC INFORMATION

36 LOTO ScanESC Auditing Procedures PUBLIC INFORMATION

37 LOTO ScanESC Auditing Employees PUBLIC INFORMATION

38 LOTO ScanESC Website Dashboard PUBLIC INFORMATION ScanESC website portal dashboard gives you secure and complete control from anywhere Identify trends to help improve your overall operational effectiveness. Ensure you stay ahead of annual auditing requirements. Verify your employees understand and are properly utilizing lockout-tagout.

39 39 Questions?

40 Thank You PUBLIC INFORMATION Rev 5058-CO900E