Plant Equipment

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Plant Equipment Systems Safety

• ISA Toronto Section
• September 27, 2007

Simon Fridlyand P. Eng
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Industrial Accidents
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Canadian Statistics

• Fatalities and Casualties in Canadian Work
  places.
• 1,097 Workplace Fatalities in 2005, up 45.
• 5 per day, 1 in 15,000 dies.
• One of the worst in 29 OECD Countries.

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Who is responsible for compliance?

• Why owner and not manufacturer?
• Owners responsibility
• New equipment PSRs
• Specifying PSRs when purchasing new equipment
• Existing/Old equipment Audits/ Upgrades

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When are the PSRs required to be conducted?

• Flammable liquids
• Machine guarding
• Racks or stacking structures
• Risk of ignition or explosion/ dust collection
• Foundry/ molten metal
• Lifting devices
• Exposure to substances

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Role of an engineer

• Engineer is responsible
• Company Engineer Vs. Outside Consultant
• Manufactures representative

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How to select a PSR provider

• Report shall have
• Hazard Assessment
• Conclusive Statements
• PSR provider shall have
• Multi Disciplines capability
• Proper Liability coverage
• Capable of providing advice
• Capable of assisting in design of solutions
• Ready to accept liabilities for his/her work

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Purchasing specification approach

• In purchasing documentation, specify SAFE
  Engineering must ensure equipment compliance
• Understand needs of Client OEM - adapt safety
  system to needs
• Drawings sent to SAFE Engineering
• Risk Assessment as part of design
• SAFE Engineering supports OEM consultation,
  design
• Equipment is pre-certified before it leaves dock
• Final inspection at installation (SAFE or
  contractor)

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History of Bill C-45, Westray Mine disaster

• Known as the Westray Bill
• Establishes OHS legal duty in Criminal Code Bill
• Reform criminal law for organizations
• Applies to federal and provincial workplaces
• In addition to existing OHS legislation
• In force effective March 31, 2004

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New Criminal Code changes related to OHS duties
(Bill C-45)

• OHS legal duty s. 217.1
• Every one who undertakes, or has the
  authority, to direct how another person does work
  or performs a task is under a legal duty to take
  reasonable steps to prevent bodily harm to that
  person, or any other person, arising from that
  work or task.

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Criminal Negligence for Individuals

• Penalties for criminal negligence
• Injury - 10 years in prison
• Death - life imprisonment

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Criminal Negligence for Organizations

• If acting within the scope of their authority
• 1. One or more representatives commits the
  offence of OHS criminal negligence
• and
• 2. Senior officer departs markedly from the
  standard of care that could reasonably be
  expected to prevent a representative from
  committing the offence

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Definition of Representative

• Representative
• Is a director, partner, employee, member, agent,
  or contractor of the organization

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Definition of Senior Officer

• Senior officer
• Means a representative who plays an important
  role in the establishment of the organizations
  policies or is responsible for managing an
  important aspect of the organizations activities
  and, in the case of a body corporate, includes a
  director, its chief executive officer and its
  chief financial officer.

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OHS Criminal Negligence for Organizations

• Penalties for criminal negligence
• UNLIMITED
• Non-tax deductible

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Due Diligence

• Successful defenses of due diligence demonstrate
  
• Identified all actual and potential occupational
  hazards (applicable to the offence). Facility
  Audit
• Assessed the risk of exposure of workers to
  hazards identified. Hazard Assessment
• Eliminated hazard or implemented controls, where
  necessary, to minimize risk of exposure to
  hazards. Equipment Upgrades.
• Communicated hazards, risks and controls to
  workers, JHSC and management

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Due Diligence

• Continued
• Monitored workers, work practices and workplace
  (equipment, machinery, facilities)
• Corrected unsafe work practices and remedied
  hazardous situations
• Disciplined worker/supervisor if they were in
  violation of their legal duties or corporate OHS
  policy or procedure
• Documented all of the above mentioned steps and
  actions

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Consequences

• Industrial mishaps fatalities and injuries
• Exorbitant costs
• Human factors
• Delays in production
• Lower productivity
• Liability
• Consequences occur because Equipment is Not Safe.

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How do you determine?

• How do you demonstrate that your operations are
  safe?
• How do you demonstrate that your equipment is
  safe?
• How do you demonstrate that your safety and
  protective systems protect against your hazards?

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What is Safe Equipment

• The Basis-Equipment Compliant to Current and
  Applicable Standards
• Represents best engineering practice
• Due diligence
• IEC61508 -Functional safety of
• electrical/electronic/programmable electronic
• safety-related systems

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What is IEC 61508 ?

• Functional Safety of electrical / electronic /
  programmable electronic safety related systems
• Mainly concerned with E/E/PE safety-related
  systems whose failure could have an impact on the
  safety of persons and/or the environment..........
  .....could also be used to specify any E/E/PE
  system used for the protection of equipment or
  product

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IEC 61508 -Key Objectives

• International standard -end users and suppliers
  operate internationally
• Generically based to facilitate the development
  of sector standards (machinery, process plant,
  medical, rail)
• Technically sound, system based approach, with
  sufficient flexibility for the future
• Provide confidence to users and regulators
• Risk based, measures proportionate to the risk
  reduction required

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IEC 61508 -Key Objectives

• Systematic approach to all safety (Product
  Process) lifecycle activities
• To enable technological developments to take
  place within an overall safety framework
• To release the potential of the (PES) technology
  to facilitate improvements in both safety and
  economic performance
• Improved efficiencies in supply chain

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Features of IEC61508

• Generic Standard to be followed by Sector
  variants
• International standard -end users and suppliers
  operate internationally
• Improved efficiencies in supply chain
• Guidance on use of Electrical, Electronic and
  Programmable Electronic Systems which perform
  safety functions
• Comprehensive approach involving concepts of
  Safety Lifecycle and all elements of protective
  systems (Other Technologies)
• Risk-based approach leading to determination of
  Safety Integrity Levels (S.I.Ls)
• Risk based, measures proportionate to the risk
  reduction required
• Considers the entire Safety Critical Loop (End to
  End)

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Safety Integrity

• The likelihood of a safety-related system
  achieving the safety functions under all the
  stated conditions within a stated period of time.

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The 7 parts of IEC61508

• Part 1 General requirements
• Part 2 Requirements for electrical, electronic,
  programmable electronic systems
• Part 3 Software requirements
• Part 4 Definitions and abbreviations
• Part 5 Examples of methods for the determination
  of safety integrity levels
• Part 6 Guidelines on the application of Parts 2
  3
• Part 7 Overview of techniques and measures

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Summary of the Key Messages in IEC 61508

• Safety Management System
• life cycle
• planning
• assessing compliance
• supply chain
• Technical Requirements
• choice of technologies
• assessment of risk
• specifications of function integrity level
• Competencies
• roles responsibilities
• skills training

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Examples of safety-related systems

• Process plant emergency shut-down systems
• Fire gas systems
• Crane automatic safe-load indicators
• Railway signalling systems
• Machinery guard/access interlocking system
• Machinery emergency shutdown
• Steam boiler controls
• Fairground roller-coaster control systems.

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Safety ProductivityProductivity Profit

• Safety productivity 2 sides - same coin
• Safety leads to higher productivity
• Payback at least 5 a year

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Contact Information

• S.A.F.E. ENGINEERING INC.
• Your safety and liability shield
• Simon Fridlyand, P.Eng
• 416-447-9757 ext 223
• www. safeengineering.ca