maintaining your safety plan - mcnaughton-mckay€¦ · functional safety life cycle safety life...

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E

PUBLIC INFORMATION

Maintaining Your Safety Plan

Safety Symposium March 2016

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 2

Functional Safety Life Cycle

Safety Life Cycle

STEP 5MAINTAIN & IMPROVE

SAFETY SYSTEM

STEP 1TEAM BASED RISK

ASSESSMENT

STEP 4SAFETY SYSTEM INSTALLATION &

VALIDATION

STEP 2SAFETY SYSTEM

FUNCTIONALREQUIREMENTS

STEP 3SAFETY SYSTEM

DESIGN & VERIFICATION

3Copyright © 2015 Rockwell Automation, Inc. All rights reserved.

• Assessments– Arc Flash Analysis

– LOTO

– Conformity Audit

– Guarding Assessment

– Basic Risk Assessment

– Team Based Risk

Assessment

• Validation

– Safety circuit analysis

– Machine stop time services

– Conformance audits

– Safety system validation

• Compliance Consulting

– CE conformance

– Functional safety (i.e., ISO

13849-1 and IEC 62061

ISO, ANSI, IEC, CE, OSHA,

NFPA, CSA, AS

Supported World Wide by Safety Professionals

Safety Services Portfolio

• Annuities– Arc Flash

– LOTO

– Validation

• Training– Safety product

training

– Safety standards training

– Arc Flash training

– TUV Certification training

• Integration / Start Up

– Circuit/logic design

– Installation

– Arc flash remediation

– MCC arc flash

upgrades

- Project Management

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION

Maintaining Safety Systems

4

Safety Culture Productive, Progressive Company

Maintenance of the Safety Program and Systems is critical

Help ensure proper safety system installation and functionality through

Safety Program & System Validation

Arc flash re-assessment

Lockout tagout (LOTO) & process improvements


Agenda

I. Validation

II. Arc Flash

III. LOTO


Program Verification And Validation

Verification & Validation

The standards require program verification & validation to ensure

• Safety system operates as intended

• Each safety function is evaluated to ensure proper operation

• If Logix– projects checked & “safety signatures” created to protect


Why Do A Validation?

8

Meets all design criteria as called for by the safety functional design

specification (SFRS), assessment and 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, reference the

need for regular verification of safety circuits


ANSI V&V Requirements part 6.8

Note – ANSI B11.0 – 2010 Safety of Machinery General Requirements & Risk Assessments


How Often do you …

10

check your Fire Extinguishers?

check your Emergency Alert System?

check your Emergency Medical Supplies?

check your Cranes?

check E-Stops?

verify light curtains work properly?

verified Guard Door Inter-lock work properly?

verified and validated that you safety system actually does what it is

supposed to do?


Safety Checklists and Validation

GuardLogix Sample checklists

• User manuals

• On-line


Sample Safety V&V Checklist for Safety Functions

• Helps with design

• Documentation “trail”

• Proof of due diligence.


Agenda

I. Validation

II. Arc Flash

III. LOTO


Arc Flash

14

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


Arc Flash Maintenance Program

15

Needs to be updated every 5 years

Maintenance of this Program may include

Site re-survey and check list(annual)

Facility power/utility analysis (annual)

News and compliance updates (annual)

Tracking of equipment changes/revisions (quarterly)

Online training & refresher (as needed / frequent)

Engineering support (unlimited)

Site Safety Policy editing & maintenance (as needed)

Energized work permits for use on every live electrical job (as needed)


Arc Flash Maintenance Program

16

Training requirements needs are continuous and are dictated by both

OSHA and NFPA 70E

The following employees require training during the year

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.


Question – Maintaining Arc Flash …

17

What if Utility Company changes power to Utility Transformer?

Do they typically inform you?


Agenda

I. Validation

II. Arc Flash

III. LOTO


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. www.escservices.com


Industry Best Practices

Lockout-Tagout Components Addressed with Industry Best Practice


Then:Now:


Employee Training

Annual Auditing

Corporate Policy


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. www.escservices.com

Now:


Then: Now:


Employee Training

Annual Auditing

Corporate Policy


Top 3 Benefits:

o Training is quicker and

less costly

o Interactive training ensures

comprehension

o Higher quality hands on

training with targeted input

\

o Interactive training online

o Employee audits with tablets

o Central cloud location for real time training status


Then: Now:


Employee Training

Annual Auditing

Corporate Policy


Top 3 Benefits:

o Audits are up to 85%

more efficient

o Higher quality data

obtained

o Data accessible in

real time

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=t9j_fXSSl3WqQM&tbnid=HrELznosHMRylM:&ved=0CAUQjRw&url=http://takecare11.blogspot.com/2012/08/computer-software-engineers-brain.html&ei=cxxHUceiNsHP0wHJ3IHgBQ&bvm=bv.43828540,d.dmg&psig=AFQjCNHC53lU2iQdOnuBlvpmz91y8K4NcA&ust=1363701152444136

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=t9j_fXSSl3WqQM&tbnid=HrELznosHMRylM:&ved=0CAUQjRw&url=http://takecare11.blogspot.com/2012/08/computer-software-engineers-brain.html&ei=cxxHUceiNsHP0wHJ3IHgBQ&bvm=bv.43828540,d.dmg&psig=AFQjCNHC53lU2iQdOnuBlvpmz91y8K4NcA&ust=1363701152444136


Then:

Now:


Employee Training

Annual Auditing

Corporate Policy


Top 3 Benefits:

o Easier to access

o Instant updates and real-

time controlled document

o Reduces chance for OSHA

fines


Then: Now:


Employee Training

Annual Auditing

Corporate Policy


Top 3 Benefits:

o Less expensive

o Easy to identify for

LOTO usage

o Quick access with

boards and kits


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?


OSHA 1910.147 Periodic Inspection Requirements 1910.147 (c)(6)

28

1910.147(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.

1910.147(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.

1910.147(c)(6)(i)(B) The periodic inspection shall be conducted to correct any deviations or inadequacies identified.

1910.147(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.

1910.147(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.

1910.147(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.


OSHA 1910.147 Employee Retraining 1910.147 (c)(7)(iii)

29

1910.147(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.

1910.147(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.

1910.147(c)(7)(iii)(C)

The retraining shall reestablish employee proficiency and introduce new or revised control methods and procedures, as necessary.

1910.147(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.


Modern Solutions for Lockout-Tagout


LOTO

ScanESC – Auditing Procedures


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.

LOTO

ScanESC – Website Dashboard


Online Resources …

35

OSHA – LOTO – Hot Topics

https://www.osha.gov/dts/osta/lototraining/hottopics/ht-overv.html

https://www.osha.gov/dts/osta/lototraining/hottopics/ht-overv.html


Online Resources …

36

ESC LOTO Services – Learning Center

https://www.escservices.com/

https://www.escservices.com/

maintaining your safety plan - mcnaughton-mckay€¦ · functional safety life cycle safety life...

Documents