Plant managers need to be aware of Lockout/Tagout, which is a safety concern that they may not be. John Garbarino Sr. recently discussed Lockout/Tagout and other electrical safety issues. Leviton Manufacturing’s Platform Product Manager, Commercial & Industrial. Here’s what he had.
Food Processing What should plant mangers know about Lockout/Tagout they might not have considered?
John Garbarino OSHA’s Control of Hazardous Energy Standard, Lockout/Tagout is a perennially cited Standard. This shows that plant managers don’t consider many things. Not only is electrical energy hazardous, but also mechanical energy. Mechanical energy, including springs, hydraulics and others. This Standard also covers these items.
A common misconception is that a Tagout-only program can be used as a substitute for a Lockout program. This is incorrect. It is possible for tags to be accidentally removed and expose workers to electrical hazards. Combining lockout with tagout programs has been shown to provide the best protection.
It is also important to consider the types of lockout hardware. To avoid confusion, it is important to clearly identify the lock types used.
The National Electrical Code has recently added that all disconnecting devices that must be locked in the open position must include the locking mechanism as an integral part. The lock cannot be removed after it has been removed.
Another misconception is that Lockout/Tagout programs are comprised of a set of locks and tags that can help to isolate equipment from energy. A Lockout/Tagout program includes detailed documentation that outlines the procedures and processes workers must follow in order to remove dangerous energy from equipment.
FP What training requirements do food processors have to meet regarding Lockout/Tagout
JG: Absolutely! OSHA Lockout/Tagout citations are often attributed to a lack of training and not hardware or program development.
Different types of employees require different levels of training: affected, authorized, and other. This training is tailored to the employee’s relationship to a particular piece of equipment. A general program that is all-inclusive is not sufficient.
Retraining is an integral part of any training program. Retraining does not have to be time-based. Other factors can also play a role in retraining employees, such as changes to the Lockout/Tagout system, new equipment, employee responsibilities, and violations of established procedures.
FP Could you please explain how motor starters can affect safety in a food facility?
JG There is a variety of manual motor starters, each designed for a specific application. Using them in an inappropriate application could pose a danger to safety. One sub-class of manual starters is “suitable for Motor Disconnect,” which means they can be used to control the motor’s on/off and also satisfy safety disconnect requirements. This type of switch, which was previously UL 508, is only allowed to be installed between the motor and the final motor branch circuit short-circuit protective device. These devices are smaller in footprint and cheaper so some people will try to use them as general-purpose disconnects switches for branch or feeder circuits, or other loads. This is a problem because the physical requirements for construction do not allow for the higher energy levels found in general-purpose environments. It is a Code violation.
FP What is the difference between weatherproofing and waterproofing an electrical device?
JG Although these terms can be confused, there are substantial differences in the performance of protecting electrical devices against harmful exposure. The confusion is partly due to the fact that “weatherproof” or “watertight”, although they are both generic terms, don’t have any formal definitions about actual protection against liquid and particle intrusion.
Weatherproof enclosures are designed to protect electronic devices from falling dirt, dust and splashing water. Some enclosures may even provide protection against hose-directed water.
FP Watertight products offer extra protection against submersion in water and high-pressure water jetting (power washing). How can you be sure which device is right for your application?
JG Two organizations, NEMA and IEC, have rating systems that specify specific criteria for protection against liquids and solids. Although there is some correlation between these ratings, and the terms “weatherproof”, “watertight”, and other terms such as “weatherproof”, they are not always accurate enough to determine whether an application is possible. Many weatherproof enclosures will have a NEMA 3R, 3S, or IP 52 rating. Watertight enclosures, on the other hand, will have a NEMA 4X, 6P, IP 65, IP66, IP67 or IP 68 rating. There are many differences in the ratings of each category. To ensure the correct enclosure, you should carefully review the protection criteria for each rating.
FP What is the most important thing for facilities to know about IP ratings for electric safety?
JG Most plant managers know the “IP Code” system. This code is two-digit and indicates how protected the enclosure is against hazardous objects, ingress of foreign objects, and water ingress.
The protection against contact and solid particle intrusion is indicated by the first digit. It ranges from 0 (no protection), to 6 (maximum coverage). A maximum rating of 6 means that protection will protect against all conditions listed in the numbers lower than 6. An enclosure rating of IP 6x will protect against dust ingress and contact with living parts.
The IP rating number’s second digit indicates how protected an enclosure is against water ingress. It can range from 0 to 9. It seems that enclosures offering water ingress protection are more protected if the number is higher than the others. Although this is true in a small way, it is not possible to assume that the second number of 9 – which is the highest – will protect from water ingress under all circumstances. For example, a rating of IP x9 protects against exposure to high-temperature/high-pressure water jetting. However, this does not automatically mean that the enclosure provides protection against submersion (which can be IP x7 and IP x8). The enclosure must have both IP x7 and IP x8 ratings if you require protection against high-temperature pressure washes and submersion. It is important to identify the exposure and cross-reference it with the IP ratings in the IEC 60529 Standard.
COVID-19 has one impact. It requires more intensive and frequent washing of areas near the production floor. Facility managers need to be familiar with IP ratings in order to install enclosures that are able to withstand the increased cleaning regimes. Do you think facilities need to know more about electrical safety?
It is important to emphasize the importance of education and training in maintaining an electrically safe facility. It can be difficult to set up and maintain these programs. Manufacturers like Leviton can assist in this area. Electrical Safety Codes, Standards and Guidelines are always changing. It is difficult to keep programs current. Leviton offers a variety of training programs to help facility managers stay current on changes, and also serve as refresher training for employees.
Leviton also produces electrical devices that support safety programs and promote electrical safety. Leviton products have safety as their core function. They include wiring devices that can be used in wet, damp or dusty environments, devices with integral lockout provisions or enhanced technology that enhances existing safety provisions.
Leviton’s Inform Technology Platform includes condition-monitoring sensors, communication elements, and alert elements. These alert users of abnormal operating circumstances, such as liquid accumulation. Remote monitoring allows for troubleshooting that doesn’t require workers to be present.
