Module 2 – Industrial Hazard Management · · 2017-01-17A Permit Required Confined Space is a confined space that ... • Inherent hazards of electricity such as exposure to voltage,

© 2013 Eaton. All Rights Reserved.

Moon Township Facility Module 2 – Industrial Hazard Management EHS Department Rev. 1

2 © 2013 Eaton. All Rights Reserved.

Course Agenda Elements Topics

Confined Space Safety (LSR) • Awareness Level Review

Electrical Safety (LSR) • Awareness Level Review

Fall Protections & Ladder Safety (LSR) • Awareness Level Review

Fire Prevention & Fire Extinguisher Use • Awareness Level Review

Energy Isolation (Lockout/Tagout) (LSR) • Awareness Level Review

Equipment Safeguarding (LSR) • Awareness level Review

Safety Signs • Awareness Level Review

Material Handling • Awareness Level Review


Confined Space Awareness Training

EHS Department Rev. 1

Life Saving Rule

4 © 2013 Eaton. All Rights Reserved. 4

Confined Spaces – Defined A confined space is defined as an area that meets ALL of the following criteria: • Large enough for a person to enter and perform work; and

• Has limited or restricted means for entry or exit that can complicate evacuation or rescue;

• and is not designed for continuous occupancy

Common confined spaces are: • Attics

• Crawl spaces

• Motor control cabinets

• Storage vaults

• Utility closets

• Dropped ceilings


Confined Spaces – Defined A Permit Required Confined Space is a confined space that exhibits one or more of the following characteristics. • Contain or potentially contain a hazardous atmosphere, such as a lack of

oxygen; or

• Contain materials that could engulf entrants; or

• Have an internal configuration which could entrap an entrant; or

• Any other recognized health or safety hazard such as rotating equipment.

Common Permit Required Confined Spaces are: • Elevator pits

• Silos

• Sewers

• Tanks

• Boilers

• Trash compactors


Confined Spaces – Labeling All permit required confined spaces must be inventoried and

labeled with a similar sign as shown below.

The intent of the labeling is to ensure all team members, contractors and visitors are aware of the hazards that are

associated with permit required confined spaces.


Confined Spaces – Prohibition The Moon Township Facility maintains a site specific Confined

Space Management Plan.

This plan prohibits the entry of a permit required confined space by all

Eaton employees.

Failure to follow this policy is an LSR violation, and will result in termination. All permit required confined space entries will be

made by trained and qualified third parties.


Confined Spaces – Prohibition Moon Township specific permit confined spaces are;

• East & West Dock Trash Compactors

• East Dock Bag House

• Dock Levelers

• Utility Manholes

• Elevator Pits

(A) (A)

(B) (B)

(C)

(C)

(D) (D)

(E)

(E)


Electrical Safety Awareness Training


Life Saving Rule

10 10

Electricity Safety Policy Eaton Moon Township maintains a site specific electrical safety policy. This policy prohibits electrical work from being performed by any individual that has NOT met general electrical safety training and electrical equipment specific training requirements. If you have not met these requirements, you are not authorized to perform any type of electrical work.

In addition, all employees are required to receive electrical safety Awareness Training. Electrical safety awareness training covers;

• Inherent hazards of electricity such as exposure to voltage, electric current, arcing, lack of grounding and guarding.

• The ability to recognize potentially hazardous energy and its potential impact on workplace conditions.


There are two primary hazards associated with electricity: • Electrical Shock - Electric shock is the leading cause of injuries and deaths due to electricity.

Approximately 30,000 nonfatal electrical shock accidents occur each year. About 1,000 electrocutions (deaths from electric shock) occur every year, more than half of them while working on conductors and equipment energized at less than 600 volts. Electric shock happens when people contact live parts or in some other way become part of an electric circuit. Even the current needed to light an old-fashioned Christmas tree bulb (7 1/2 watts, 120 volts) is enough to kill a person if it passes across the chest and through the heart.

• Arc Flash/Blast - When electric current passes through the air, temperatures can get hot enough to ignite clothing, melt plastic and burn people’s skin up to 10 feet away. Each year more than 2,000 people are admitted to hospitals with arc-flash burns. In addition to burn danger, the very bright light associated with an arc-flash events can cause temporary (and sometimes permanent) blindness. Arc-flashes are usually short events lasting less than a half-second. They can be caused by such things as dropping a tool or metal part across energized equipment, operating damaged electrical equipment or voltage testing with a meter that isn’t properly rated.

Electricity Fundamentals

Electric Shock

Arc Flash/Blast

12 12

Electricity Fundamentals The more amps in an electrical circuit, the more dangerous it becomes.

Effects of Amps on the Human Body at 60hz AC


Cords & Equipment • Visually inspect electrical equipment before each use for damage and/or external defects such as

loose, missing or deformed parts and / or pinched , crushed or frayed outer jackets or insulation. This type of external damage may indicate internal damage to the equipment.

• Electrical cords that are worn or damaged must be replaced without delay • Missing ground prong • No running cords through doorways, windows or walls • Before cleaning electrical equipment, turn it off and unplug it.

Electrical Panels • Electric panels must be kept clear of any obstructions at all times. • Storage is not allowed in front electrical equipment or service panels. Find another place for

storage of materials, products, etc.

Electrical Safety – Hazard Recognition


Trip Hazards • Don’t cause tripping hazards or create pinch points for cords. • If you must run a cord temporarily across the floor, protect your co-workers by covering the cord

appropriately.

Exposed Wiring • Assume all exposed wiring is energized until proven otherwise. • Stop, protect the area, and contact supervisor if you encounter this situation.



Power Strips • Never “daisy chain” multi-outlet strips (plugging into each other) • Power strips must be plugged into wall outlets • Power strips must not be permanently affixed to the structure or furniture

Junction boxes, pull boxes • Fittings must have approved covers in place. • Unused openings in cabinets, boxes, and fittings must be closed (no missing knockouts). • Report these situations to the facilities department



Signs that electrical work is being performed • The use of warning barricades or signs to establish hazard identification areas, or approach

boundaries. • Use of warning lights during electrical testing • Qualified individuals will communicate with affected individuals prior to electrical work being

performed.


Occupied


Approach boundaries are established when performing live work. Non-qualified individuals are not authorized to enter the approach boundaries without being escorted by a qualified person.

When barricades or signs are posted, DO NOT ENTER!

Electrical Safety – Approach boundaries Defined


Fall Protections & Ladder Safety Awareness Training


Life Saving Rule


Fall Hazard Management

Hazard elimination is accomplished by evaluating work to be performed at height and identifying methods to perform the work at ground level.

Note: An Elevated Work Permit is required whenever fall arrest equipment is required.

Fall prevention is accomplished through the use of covers over floor opening or the installation of permanent work platforms equipped with handrails on all exposed sides .

A fall arrest system will be used when fall prevention techniques such as handrails or covers are not feasible .

Eaton team members MAY NOT work at unguarded work surfaces at heights greater than 6 feet, unless they are trained and authorized to use fall arrest/restraint equipment.

Every effort will be made to eliminate unguarded work locations. The below hierarchy of controls will be used when assessing the best possible solution to reduce the fall hazard.


Step Stools

• Typically used for low level access to equipment, supplies, etc. at low heights. They can also be used to sit on to perform work.

Note: standing on top step is permitted on step stools. Standard design is top platform and 2 or less steps. • LSR Impact - Due to the limited

height, when used properly, they would not require additional fall protection measures or fall arrest systems.


Step & Extension Ladders

• Widely used for portable access. Design options include multiple heights and configurations including twin/double sided access. Designed for limited space areas. Note: Per MESH requirements, construction must be non-conductive. Standing is not allowed above designated step. Must have legible and visible specification labels. See ladder for specific restrictions.

• LSR Impact - Employees must maintain 3 points of control during work and climb. Work must be performed without over-reaching, i.e. belt buckle within stiles. If user can not meet those requirements and their feet are above 6 feet during use, then a fall arrest system is required.


Work Platforms • Provide access to elevated work

areas, both permanent and temporary. Design options include fixed, as well as, rolling/ mobile designs. Compliant designs include railing systems around the standing platform to prevent falling.

• LSR Impact - When used properly, fall arrest is not required even if the platform height is located above 6 feet. However, employee should always be facing forward when climbing up or down and the device is subject to general use requirements, including inspections.

Work platforms shall NOT be used for any electrical work.


3-Points of Control – Defined

• Any combination that includes 3 of the following (when centered on ladder) • Foot • Hand • Midsection / torso

Not Centered 2-points of contact


Ladder Safety Visual Inspections

• Portable ladders or platforms should be inspected before each use to verify:

• Steps securely attached to side rails; • Fittings securely attached; • Safety feet are securely attached; • Steps are free of defects; • Steps are free of slippery substances; • Metal parts are free of corrosion; and • Ropes are not frayed or worn

Visual inspections before each use Documented portable ladder inspections Documented fixed ladder inspections annually


Fire Prevention & Fire Extinguisher Use Awareness Training



Workplace fires and explosions kill 200 and injure more than 5,000 workers each year.

75,000 workplace fires cost businesses more than $2.3 billion annually.

Fire Prevention

Work place fires can not be sustained unless all three elements of the Fire Tetrahedron are present.

The best way to prevent a workplace fire is to eliminate excess or undesired elements of the fire tetrahedron. Oxygen at normal atmospheric levels is desired in most work environments. That leaves us with the ability to control heat/ignition sources, fuel sources or the chemical chain reaction .

By eliminating ignition sources and excess combustible/flammable materials, we can greatly reduce the possibility of a workplace fire occurring.

Call me crazy, air is normally

desired in the work

environment…..

Uninterrupted Chemical Chain Reaction

Paper, cardboard,

plastics, chemicals,

wood, carpet, etc.

Open flames, Welding, cutting, grinding,

Electrical testing, Appliances,

Smoking


Fire Prevention - Control of Fuel Sources Good housekeeping is the first rule of fire prevention and must be a concern of everyone in the facility.

Housekeeping is more than just cleanliness. It includes keeping work areas neat and orderly; maintaining halls and floors free of slip and trip hazards; and removing of waste materials (e.g., paper, cardboard,) and other fire hazards from work areas.

Access to emergency equipment (fire extinguishers, eye wash stations, spill kits, first aid kits, etc.) shall be constantly maintained. Where practical, striped tape has been applied to the floor around emergency equipment and the area within the striped tape shall not be breached.


Fire Prevention – Control of Ignition Sources Hot work - is any work that generates heat, sparks, or open flames that can ignite flammable or combustible materials in the work area. All hot work is a fire hazard. If not managed properly, hot work can result in property loss or injuries to employees, contractors or visitors. Since hot work is introducing an ignition source in the work environment, all hot work must be conducted in a designated hot work area, or must be approved by the use of a hot work permit.

Hot work includes, but is not limited to, the following activities:

• Welding • Grinding • Brazing or soldering • Use of torches or other equipment

that generates an open flame • Or other spark producing tasks

=

29 © 2012 Eaton Corporation. All rights reserved.

Fire Prevention Plan

The Moon Twp. facility is required to maintain a fire prevention plan that identifies major fires hazard in the work environment, and the control devices used to reduce the potential of a work place fire.

The adjoining table details our major fire hazards, and the control measures that are in place.

Major Fire Hazards Potential Ignition Sources Control Measures Fire Protection Equipment

Electrical Testing

Electrical arcing

Thermal exposure

Failure testing

Inspections/Gemba

Standard work documentation

Sprinkler system

Portable fire extinguishers

Use of solvents

Smoking

Static electricity

Hot work

Electrical Testing

No smoking on campus

Bonding and grounding

Flammable liquids cabinets

Minimum use containers

Hot work permit system

Inspections/Gemba

Weld Shop Various forms of welding

Designated Hot work area

Inspections/Gemba

Wood Packaging

Smoking

Hot Work

Electrical Testing


Hot work permit system Inspections/Gemba

Corrugated Packaging

(cardboard)

Smoking

Hot Work

Electrical Testing



Inspections/Gemba

Paint Booth Filters Smoking

Hot Work



Waste handling procedures

Inspections/Gemba

Lubricants

Smoking

Hot Work

Electrical Testing



Inspections/Gemba

Kitchen Oils Smoking

Hot Work



Inspections/Gemba

30 30

In the event a fire does occur, the following actions should be taken; • Know area emergency procedure and evacuation routes • Know location of extinguishers in your area and how to use them • Always sound the alarm regardless of fire size • Avoid smoky conditions • Ensure area is being evacuated • Don’t attempt to fight unless:

• The Fire Alarm is sounded • The Fire is small and contained • You have a safe egress route (can be reached without exposure to fire) • Available Fire Extinguishers are rated for size and type of fire

• If in Doubt, just Get Out!

Fire Extinguisher Use


Anatomy of a Fire Extinguisher

32 32

PULL the pin out: This unlocks the operating lever and allows you to discharge the extinguisher. AIM low: Point the extinguisher nozzle (or hose) at the base of the fire. SQUEEZE the lever above the handle: This discharges the extinguishing agent. SWEEP from side to side: Moving carefully toward the fire, keep the extinguisher aimed at the base of the fire until the flames are out

Fire Extinguisher Use

If the fire does not go out or increases in size, do NOT use additional fire extinguishers – Evacuate the building!!


Energy Isolation (Lockout/Tagout, LOTO) Awareness Training


Life Saving Rule


What is Energy Control?

Energy control is the process of turning off a piece of equipment, placing a lock on each source of hazardous energy and releasing stored energy in order to bring the equipment to a zero energy state.

Energy control is more commonly referred to as “Lockout/Tagout or LOTO”.


When is Energy Control Required?

LOTO procedures must be followed when a guard, fixed panel, or safety device is opened, removed, bypassed; or any part of the body is placed into an area where injury could result if the equipment were to start, or be energized unexpectedly.

Examples of tasks that might require LOTO include maintenance activities, adjustments, machine setup, electrical tester setup, tool changes, cleaning and jam removal.


Types of Employees

Authorized Employees • A person who actually applies

locks or tags to machines in order to perform servicing or maintenance.

• They receive additional training on how to perform Lockout/Tagout.

Affected/Other Employees • A person who works in an

area where Lockout/Tagout might be performed.

• All employees fall in this category.

There are two types of employees involved in the LOTO process. They are:

This training does not authorize you to perform LOTO!


Understanding Hazardous Energy

Hazardous energy is defined as, any level of energy present in a piece of equipment that can cause unexpected activation, start-up, or movement that can cause injury.

Types of hazardous energy include:

• Electrical • Pressurized Air • Chemical • Hydraulic (Fluids Under Pressure) • Water • Thermal (Hot or Cold Substances) • Stored Energy


Understanding Hazardous Energy • Each person authorized to perform lockout

must place a lock on all prescribed sources of hazardous energy if they are to work on or enter into the hazardous location.

• Specific lockout steps are outlined in

equipment-specific lockout procedures located at individual workstations or equipment.

• Persons who are not authorized to perform lockout activities must never attempt to start a machine that is locked out or attempt to remove another person’s lock.


LOTO Devices If you see any device similar to these DO NOT tamper with or try to remove!

Valve Lockout

Switch Plate Lockout Plug Lockout Ball Valve Lockout

Single Pole Lockout Lock Hasp

LOTO Tags

LOTO Cable


Equipment Safeguarding Awareness Training



Equipment Safeguarding - General While we make every effort to isolate industrial process within restricted access locations, there is equipment accessible throughout this facility.

Only trained and authorized individuals are permitted to operate machines or test equipment.

If you are a person that is responsible for acquiring new/used equipment, it is your responsibility to ensure safeguarding requirements are met, or plan to be met, prior to equipment being placed into service. Failure to provide adequate guarding will result in equipment being removed of service until corrective actions can be performed.

For additional information pertaining to equipment safeguarding requirements, follow the below links. Machine Safeguarding Project Management Handbook Machine Safeguarding Specifications for New Equipment

http://wcm-prod-cs.etn.com/Corp_EHS/MESH/MESHStructure/8.0ProcessSafety/MachineGuarding/idcplg?IdcService=GET_FILE&RevisionSelectionMethod=LatestReleased&Rendition=Primary&dDocName=PCT_257446

http://wcm-prod-cs.etn.com/Corp_EHS/MESH/MESHStructure/8.0ProcessSafety/MachineGuarding/idcplg?IdcService=GET_FILE&RevisionSelectionMethod=LatestReleased&Rendition=Primary&dDocName=PCT_258876


Equipment Safeguarding - General Any electrical exposure, equipment part, function, or process that may cause injury must be safeguarded. When the operation of a machine/tester, or accidental contact with it can injure the operator or others in the vicinity, the hazards must be either controlled or eliminated. Hazardous energies that require guarding are;

• Electrical Hazards • Point of operation • Power transmission apparatus • Other moving parts • Hazardous Motions include rotating, reciprocating and transverse • Hazardous Actions include cutting, punching, shearing and bending. • High Pressure Systems • Other Substances such as chemicals, cutting fluids and coolants

Equipment guarding must never be removed by an unqualified individual. Tampering, removing or otherwise voiding the guards effectiveness is a LSR

violation.


Safety Signs Awareness Training



Employers have a responsibility to warn their employees about hazards that exist in the workplace. One of the easiest ways to accomplish this to follow established safety sign and marking requirements OSHA has three classifications of signs, classified according to use: 1. Danger signs—Indicate immediate danger and that special precautions

are necessary. OSHA also specifies that the red, black and white colors used for Danger signs be in accordance with ANSI Z535.

Safety Signs

Example of a danger sign. Other danger signs are present at this facility.

http://www.grainger.com/category/ecatalog/N-h9e/Ntt-1.%09Danger+Signs


2. Caution signs—Warn against potential hazards or caution against unsafe practices. OSHA specifies that the standard color for Caution signs shall have a yellow background, black panel and yellow letters. All letters used against the yellow background shall be black. Z53. 1 -1967.

Safety Signs

Example of a caution sign. Other caution signs are present at this facility.

http://www.grainger.com/category/safety/ecatalog/N-bit/Ntt-Caution+Signs


3. Safety instruction signs—Used where there is a need for general instructions and suggestions relative to safety measures. OSHA specifies that the standard color for Safety Instruction signs shall be a white background, green panel and white letters. Any letters used on the white background shall be black. The colors must be in accordance with ANSI Z535

Safety Signs

Example of a safety instruction sign. Other

safety signs are present at this facility.

http://www.grainger.com/product/ACCUFORM-First-Aid-Sign-9LLL8


In addition to previously mentioned signs, Moon Twp. has adopted ANSI’s standards for floor markings. ANSI’s floor marking standard is as follows,

Safety Signs

All safety signs and floor markings communicate important safety information and should be followed at all times.


Material Handling, Pedestrian Safety, Move Permits Awareness Training EHS Department Rev. 1


Material Handling 1 out of every 6 Eaton recordable injury is a result from material handling tasks.

From September 2015 thru March 2016

Common injures are;

• Lifting, moving, storing materials resulting in fractures, crushes; severe injuries to back, hands, feet, etc. especially when handling heavy materials

• Ergonomic sprains, strains, etc.

• Pedestrian and material handling traffic collisions

• Pallets as trip hazards

• Carts, bins, trollies, shelving – unstable, incorrect for the job, or poorly maintained


Material Handling Whether in an office or an industrial setting, material handling is a fact of life. Materials must be moved from point A to point B, and many times this is done by hand.

Each persons physical ability varies depending on multiple factors, but there are a few common sense techniques that can greatly reduce your chance of injury. If you are not able to easily lift the object, or if it exceeds 50lbs, you should get someone else to help you, or utilize mechanical assistance. The take away of this guidance is NOT a 50 lbs weight restriction. It is to know

you capabilities, and do not exceed what you can comfortably do. If you need help, get help!


Material Handling The preferred method for material movement is the use of mechanical assistance. The use of Powered Industrial Truck (PIT), carts and dollies are extensively used at the Moon Twp. facility. • Material handling equipment must be placarded with maximum capacity. The

maximum capacity must never be exceeded. • Material handling equipment should always be inspected to ensure it’s in working

conditions. If a defect is identified, it should be removed from service. • Only trained and authorized individuals are permitted to operate PIT equipment. • Pedestrians need to be aware of there surroundings and avoid material handling

operations.


Move Permits - Guidelines for moving equipment & machinery >70lbs.

If you are planning on moving equipment or machinery in excess of 70 lbs, you are responsible for obtaining a move permit and the appropriate approvals. The following action should be taken when planning a move: • A “Principal in Charge” must be named to lead the coordination of the move. This is usually

the person requesting the move or the project manager. • A “move team” (Eaton employees, contractors or otherwise) must be designated. The plan

must be reviewed with the team and they must sign off on the plan. • In addition, all permits must be signed off within 72 hours prior to the move by the Area

Supervisor and an EHS Representative. • After completion of the move, the permit must be submitted to the EHS Department for

retention. Follow this Link for additional information

on move permits.

http://teams.etn.com/es/MoonTownshipEHS/Moon%20Township%20EHS%20%20Documents/1%200%20Moving%20Equipment.pdf


For additional information contact:

EHS Manager – Chris Tanner Phone: (412) 893-4033 Email: [email protected]

EHS Technician – Chuck Bates Phone: (412) 893-5800 Email: [email protected]

Moon Township EHS SharePoint Site

mailto:[email protected]

mailto:[email protected]

http://teams.etn.com/es/MoonTownshipEHS/default.aspx