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)Safety and the Law of
Unintended
Consequences
“No Group of
Engineers in a
Boardroom can
ever Anticipate
what Normal
People will do with
their Inventions“(Peter Thelen, LBWL)
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What is Mechanical
Engineering?
• Application of principles from physics and
materials science.
• Requires a solid understanding of core concepts
including mechanics, kinematics,
thermodynamics, fluid mechanics, heat transfer,
materials science, and energy.
•robotics heating and cooling
systems
•motor vehicles,
•medical devices •manufacturing plants •aircraft
•machinery •industrial equipment •watercraft
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What is Safety?
To the Engineer
• Reliability – Takes great pride that the equipment will operate as designed.
• Planning, Design, Operational Procedures, Training
• Remember - What you design can hurt people!!!!!
To Everyone Else
• Human Factors – “Why bad things happen to good people”
• Man-machine relationship – “Who in their right mind put the valve against the wall with 6” clearance?”
• Exposure – chemicals, noise, pathogens, radiation
• Ergonomics – repetitive stresses, lifting, twisting, vibration
• And things you never even thought of!
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The Engineer is in the Middle
Problem
to Solve
Use it
Safely
Build it Safely
Do not create a
bigger
problem
Design
Challenge
New
Ideas
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Occupational Safety and
Health Administration
OSHA
General Duty Clause
The employer is
responsible to provide a
safe work place
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Michigan Occupational Safety
& Health Administration
MIOSHA
140 General
Industry
59 Construction
6 Administrative
24 Agriculture
1,000’s of pages !!!
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Consensus Standards
• ANSI - American National Standards Institute
• ASTM - American Society for Testing and Materials
• NFPA – National Fire Protection Association
• Electrical, mechanical, medical, etc
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Engineering Design &
Hazard Control
Administrative
Engineering
Hot
work
Permit
Confined
Space
Lock
Out –
Tag
Out Protective
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Engineering ControlsRemove or reduce the Hazard
Make sure the solution is not worse than the original hazard
Administrative ControlsRemove or reduce the Exposure
Manages but does not remove the hazard
Personal Protective Equipment (PPE)Protective Barrier
Only provides a barrier that is not fail safe
The Hierarchy of Controls
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Personal Protective
Equipment
1. Least effective
2. Last line of defense when:
a. Exposure can not be removed
b. Administrative controls cannot
provide sufficient protection
3. Equipment that puts a barrier
between worker and hazard
4. Does not remove the hazard
Gloves, Hard Hat,
Safety Glasses,
Face shield,
Clothing, Shoes,
Hearing Protection
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Design for Safety
• Contractor has to install it
• Operations has to use it
• Maintenance has to fix it
• Everyone else has to live with it
$$Estimate 1,000 times more expensive
to redesign after installation
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------ Behind here to work ???
How do you get
this ---
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Control
Accessibility
• Visible
• Preferred at ground
level or fixed platform
• Readily available for
emergency shutdown
Pressure
gauge & sight
glass
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A Portable
Step Ladder
should not
be
permanent –
That’s why
they are
called
portable !!!
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How
do
you
get
from
here?
To
Here
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Through
here
So we can
get to this
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Keep a clear
path to Safety
Showers and
Eye Wash
Stations &
Fire
Extinguishers
Safety Equipment Accessibility
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Working Aloft
First Rule is
Prevention
Railings
Barriers & Structures
Scaffolds
Ladders
Personnel-lifts
Safety Harnesses
Attachment points
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Fall Restraint
• Prevent the worker
from “going over the
edge”
• Attachment point &
cable – 2 times
expected load.
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Fall Arrest System
Last resort for Fall Protection
When you fall you will not hit the
ground!!
• Engineered attachment point to
withstand 5000 lbs
• Free fall limit of 6 feet
• Swing clearance
• Rescue plan – 30 minutes or
less
– Orthostatic intolerance (suspension
trauma) Restricted Blood circulation
– Blood pooling
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Sound levelsHearing damage is
permanent !!
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Sound Levels
Operating at Full Load
115 -125 dB
8 hour exposure is exceeded in 15 minutes
Engineering Controls are the Most Effective
Hearing protection is the method of last resort.
Caterpillar 2MW generator
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Drains
Remember water runs
down hill !!!
Floor drains should
be close to the
equipment drain
Floor
Drain
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Confined Spaces
• Limited Access
• Air Monitoring
Carbon Monoxide
has no warning
signs and is
deadly
• Emergency
rescue
• Training
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Machine Guarding
• Power presses
• Robotics
• Saws
• Grinders
• Machine shop
equipment
Have to be able to do the work with the guard
in place.
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Muscles
Tendons
Ligaments
Joints
Blood vessels
Nerves
Work Related Musculo-
Skeletal Disorders (WMSD)
Occupational
disorders of the
soft tissues
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Lifting
References
http://www.ccohs.ca/oshanswers/ergonomics/niosh/calculating_rwl.html
http://www.emcins.com/lc/niosh.htm
http://wisha-training.lni.wa.gov/training/presentations/CommonWMSD.pps#1
http://wisha-training.lni.wa.gov/training/presentations/Lifting%20Hazards.ppt
• There are 50,000 Work Related Musculo-Skeletal Disorders (WMSD) in Washington State every year.(2002 data)
• How many of them are due to lifting?
17,000! (34%)
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Lifting Injuries Aren’t Just
Back Injuries
30% of Shoulder WMSDs
22% of Elbow
WMSDs
13% of Hand/Wrist
WMSDs
43% of Back
WMSDs
Lifting results in:
Source: SHARP technical report No. 40-6-2002
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Reduce Heavy Lifting
• Reduce the weight
• Increase the weight
distribution
• Use mechanical
assistance
• Slide instead of lift
• Team lifting
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Other Ergonomic Stress
Factors
• Repetitive - Computer use,
assembly line work
• Vibration – Jack hammer,
construction activities
• Twisting and pulling
• Reaching and over extension
• Posture – Crawling, working in
small spaces
• Static stress – Same posture for
long periods of time
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Spot says, “it’s HOT out there!”
“Be sure you’re drinking plenty
of water!”
Heat Illnesses
Heat Stress – rash,
fainting, cramps,
exhaustion
Heat Stroke - Core body
temperature >105 o F
Life threatening
condition!!!
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Hypothermia & Frost Bite
Hypothermia ("low heat”) Body fails to maintain its normal core temperature of 98.6°F.
Frostbite - Deep layers of the skin and other body tissues freeze (<28°F-30°F). Ice crystals form, destroying tissues and causing
permanent damage.
Hypothermia is a medical emergency!
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Chemical Safety
• Material Safety Data Sheets (MSDS)
• Substitute a less hazardous material
• Employee exposure
• Spill Response
• Containment structures
• Storage and disposal
• Environmental requirements
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Hazardous Energy Control
Lockout \ Tag Out
(LOTO)
Equipment must be
able to take a lock
Location of lock
must be accessible
Electrical, mechanical, chemical,
pressure, thermal, pneumatic,
gravity, hydraulic
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Housekeeping and Storage
• Design places for
accessible tool
storage
• Provide work
spaces and work
benches
• Wash stations and
sinks
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Combustible Dust
Since 1980, there have
been at least 350 dust
explosions in the U.S.,
killing 133 people and
injuring hundreds more.
There are at least 30,000
factories in the nation
vulnerable to dust
explosions
•Youtube hyperlink
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Combustible Atmosphere
Dust, gas vapor
Ignition Source
OxygenExplosive when concentration is between the LEL
& UEL!
Combustible Atmosphere
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Combustible Atmosphere
Dust Ignition Source
Oxygen
Combustible Atmosphere
SuspensionConfinement
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Slips Trips & Falls
• Most falls (injury/death) are from less
than 6 feet.
• 15 % of all accidental deaths
(≈12,000/year)
• 2nd leading cause behind motor vehicles
• About 25% of reported injury claims per
year
• > 17% of all disabling work injuries are
the result of falls
MANY OF THESE COULD HAVE BEEN PREVENTED
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Slip, Trip, Fall Definitions
Slip - too little friction or traction between your feet (footwear) and the walking or working surface, and you
lose your balance.
Trip - foot (or lower leg)
hits an object and your upper
body continues moving,
throwing you off balance.
Fall
Occurs when you are
too far off your center of
balance.
Friction: The resistance encountered when an object (foot) is moved in contact with another (ground). Friction is necessary in order to walk without slipping.
orWhen you step down unexpectedly to
a lower surface (Misstep) and lose your
balance, e.g., stepping off a curb.
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Causes of Slips, Trips, Falls
• Falls - same level,
lower level
• Contamination of
surface
• Highly polished
surfaces
• Unexpected height
or transition
• Slopes, uneven
terrain
• Weather conditions
• Rug, mats
• Inappropriate shoes
• Inattention
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You have a Great
Responsibility
But you are not alone
Use your resources
– Operators
– Maintenance staff
– Professional
colleagues
– Even the regulators can
help !!!
46
Irene Armock, Certified Industrial Hygienist
Lansing Board of Water & Light
Safety Department
PO Box 13007
Lansing Michigan 48910
Phone: 517-702-6385
Cell Phone: 517-388-6385
E-mail: [email protected]
Good Luck &
Have a Safe Day !!!
