Failure Mode And Effect Analysis (FMEA)

FAILURE MODE AND EFFECT ANALYSIS (FMEA)

            This is an analytic technique, which explores the effects of failures or malfunctions of individual components in a system – i.e., “if this part fails, in this manner, what will be the result?”. First the system under the consideration must be defines, so that system boundaries are established. Thereafter the essential questions are:

1. How can each component / part fail?
2. What might cause these modes of failure?
3. What could the effects be if the failures did occur?
4. How serious are these failure modes?
5. How is each failure mode detected?

An example FMEA worksheet:

Component / part	Potential failure mode	Potential effects of failure	Severity	Potential causes of failure	How will failure be detected	Action to control risk
Bulb	Filament break	No illumination	/	Voltage too high	Human visual	Regulate voltage
Bulb	implosion	Etc.,

NOTE: There are many software's available for FEMA, the format of one differs to another.

The level of risk determined by Risk Matrix

Or         RISK = PROBABILITY OF FAILURE X SEVERITY CATEGORY

Where severity may be categorized thus:

Category	Degree	Description
I	Minor	Functional failure of part of machine or process – No potential injury
II	Critical	Failure will probably occur without major damage to system or serious injury
III	Major	Major damage to system another potential serious injury to personnel
IV	Catastrophic	Failure causes complete system loss and / or potential or fatal injury

And probability may be categorized thus:

Level	Probability	Individual Failure Mode
A	Frequent	Likely to occur frequently.
B	Probable	Likely to occur several times in the life of an item.
C	Occasional	Likely to occur sometime in the life of an item.
D	Remote	Unlikely to occur but possible.
E	Improbable	So unlikely that occurrence may not be experienced.

Application:

                     A practical application of the FEMA technique would involve the completion of a worksheet in which the failure modes of individual components, such as relays and switches, are identified, evaluated and risk priority codes identifies. A summary sheet can then be prepared in which failure modes are listed in declining order or risk priority codes. The summary should also list the corrective measures required to reduce the frequency of failure or to mitigate the consequences. Corrective actions could include changes in design, procedures organizational arrangements e.g. the additional of redundant features and detection methods or a change in maintenance policy may be suggested.

                   FMEA can be used for single point failures but can be extended to cover concurrent failure modes. It can be a costly and time consuming process but once completed and documented it is available for future reviews and as a basis for other risk assessment techniques such as Fault Tree Analysis and Event Tree Analysis.

What if Analysis

“WHATIF” HAZARD ANALYSIS

                   “What–If” Hazard Analysis is a structured brainstorming method of determining what things can go wrong and judging the likelihood and severity of those situations occurring. The answers to these questions form the basis for making judgments regarding the acceptability of those risks and determining a recommended course of action for those risks judged to be unacceptable.

                   Assembling an experienced, knowledgeable team is probably the single most important element in conducting a successful “WhatIf” analysis. Individuals experienced in the design, operation, and servicing of similar equipment or facilities are essential. Their knowledge of design standards, regulatory codes, past and potential operational errors as well as maintenance difficulties brings a practical reality to the review. Team members may include the P.I., Laboratory Manager, RM&S representative(s), and representatives with specific skills, as needed (maintenance rep., compressed gas rep., manufacturer rep. etc.).

                The next most important step is gathering the needed information. The operation or process must be understood by the review team. If these documents are not available, the first recommendation for the review team becomes clear. Develop the supporting documentation! Effective reviews cannot be conducted without updated reliable documentation. An experienced team can provide an overview analysis, but not without proper documentation. 

“WhatIf” questions can be formulated around human errors, process upsets, and equipment failures.

The questions could address any of the following situations:

• Failure to follow procedures or procedures followed incorrectly
• Procedures incorrect or latest procedures not used
• Operator inattentive or operator not trained
• Procedures modified due to upset
• Process conditions upsets
• Equipment failure
• Instrumentation miscalibrated
• Debugging errors
• Utility failures such as power, steam, gas
• External influences such as weather, vandalism, fire
• Combination of events such as multiple equipment failures

             To minimize the chances that potential problems are not overlooked, moving to recommendations is held until all of the potential hazards are identified.

           The review team then makes judgments regarding the likelihood (e.g., unlikely, possible, quite possible) and severity (e.g., minor, serious, very serious) of the “WhatIf” answers. If the risk indicated by those judgments is unacceptable then a recommendation is made by the team for further action. The completed analysis is then summarized and prioritized, and responsibilities are assigned.

Measures of Flammability

MEASURES OF FLAMMABILITY

             Several terms are important when evaluating the flammability of a material.The flash point is the temperature at which a liquid gives off sufficient vapors for an external ignition source to cause a flame to flash across the surface of the liquid.

However, if the ignition source is removed, the flame will go out because self sustained combustion is not possible at this temperature. Several methods are available for testing flash point; Tag Closed Cup ASTM D-56, Tag Open Cup ASTM D-1310, Cleveland Open Cup ASTM D-92, and Pensky-Martens Closed Cup ASTM D-93.



The ignition temperature or fire point is the temperature at which the material will begin self-sustained combustion if an external ignition source is used to initiate the process. This temperature is usually only slightly higher than the flash point. The auto-ignition temperature is the point at which the material has been sufficiently heated for combustion to occur without an external ignition source.

The flammable or explosive range identifies the percentage mixture of flammable vapor or gas in air that can be ignited. The flammable range is the area between the upper (UFL) and lower (LFL) flammable limits, also referred to as explosive limits (UEL and LEL). Gasoline, for example, has a lower flammable limit of approximately 1.5 and an upper flammable limit of approximately 7.5. This means that if its vapors are mixed in the surrounding air between 1.5 and 7.5%, and an ignition source is introduced, it will burn or explode. If the percent of vapors in air were 1%, the mixture would be too lean to burn because sufficient fuel would not be present. If the percent of vapors in air were 10%, the mixture would be too rich to burn because there would be too much fuel relative to the oxygen.


Figure illustrates a comparison of flammable ranges for several common substances. A solid material’s contribution to a fire is most commonly measured by its ease of ignition, flame spread, and smoke production. For testing and evaluation, solid materials are usually grouped into two primary categories: flexible solids, which include upholstery, furniture cushions, and clothing, and structural solids, which include solid building materials whether they are used in the structure or the contents.


Ease of ignition is tested to provide information about how much and how long heat must be applied to ignite the material under consideration. Flame spread addresses the speed at which a fire, once ignited, will travel across the surface of the material. Flame spread testing is typically done in a Steiner Tunnel. One example of a test standard is NFPA 255 Standard Method of Test of Surface Burning Characteristics of Building Materials. Smoke production has traditionally been evaluated based on the amount of visible smoke and not on the chemical composition of the smoke. The current trend is toward more accurate measurement of the smoke’s toxic components that may produce detrimental effects on people in a fire situation.

Scaffolding Safety basic definitions

Scaffolding Safety Basic Definitions

Adjustable suspension scaffold: means a suspension scaffold equipped with a hoist(s) that can be operated by an employee(s) on the scaffold.

Bearer (putlog): means a horizontal transverse scaffold member (which may be supported by ledgers or runners) upon which the scaffold platform rests and which joins scaffold uprights, posts, poles, and similar members.

Boatswains' chair: means a single-point adjustable suspension scaffold consisting of a seat or sling designed to support one employee in a sitting position.

Body belt (safety belt): means a strap with means both for securing it about the waist and for attaching it to a lanyard, lifeline, or deceleration device.

Body harness: means a design of straps which may be secured about the employee in a manner to distribute the fall arrest forces over at least the thighs, pelvis, waist, chest and shoulders, with means for attaching it to other components of a personal fall arrest system.

Brace: means a rigid connection that holds one scaffold member in a fixed position with respect to another member, or to a building or structure.

Bricklayers' square scaffold: means a supported scaffold composed of framed squares which support a platform.

Carpenters' bracket scaffold: means a supported scaffold consisting of a platform supported by brackets attached to building or structural walls.

Catenary scaffold: means a suspension scaffold consisting of a platform supported by two essentially horizontal and parallel ropes attached to structural members of a building or other structure. Additional support may be provided by vertical pickups.

Chimney hoist: means a multi-point adjustable suspension scaffold used to provide access to work inside chimneys. (See "Multi-point adjustable suspension scaffold".)

Cleat: means a structural block used at the end of a platform to prevent the platform from slipping off its supports. Cleats are also used to provide footing on sloped surfaces such as crawling boards.

Competent person: means one who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.

Continuous run scaffold (Run scaffold): means a two-point or multi-point adjustable suspension scaffold constructed using a series of interconnected braced scaffold members or supporting structures erected to form a continuous scaffold.

Coupler: means a device for locking together the tubes of a tube and coupler scaffold.

Crawling board (chicken ladder): means a supported scaffold consisting of a plank with cleats spaced and secured to provide footing, for use on sloped surfaces such as roofs.

Deceleration device: means any mechanism, such as a rope grab, rip-stitch lanyard, specially-woven lanyard, tearing or deforming lanyard, or automatic self-retracting lifeline lanyard, which dissipates a substantial amount of energy during a fall arrest or limits the energy imposed on an employee during fall arrest.

Double pole (independent pole) scaffold: means a supported scaffold consisting of a platform(s) resting on cross beams (bearers) supported by ledgers and a double row of uprights independent of support (except ties, guys, braces) from any structure.

Equivalent: means alternative designs, materials or methods to protect against a hazard which the employer can demonstrate will provide an equal or greater degree of safety for employees than the methods, materials or designs specified in the standard.

Exposed power lines: means electrical power lines which are accessible to employees and which are not shielded from contact. Such lines do not include extension cords or power tool cords.

Eye or Eye splice: means a loop with or without a thimble at the end of a wire rope.

Fabricated decking and planking: means manufactured platforms made of wood (including laminated wood, and solid sawn wood planks), metal or other materials.

Fabricated frame scaffold (tubular welded frame scaffold): means a scaffold consisting of a platform(s) supported on fabricated end frames with integral posts, horizontal bearers, and intermediate members.

Failure: means load refusal, breakage, or separation of component parts. Load refusal is the point where the ultimate strength is exceeded.

Float (ship) scaffold: means a suspension scaffold consisting of a braced platform resting on two parallel bearers and hung from overhead supports by ropes of fixed length.

Form scaffold: means a supported scaffold consisting of a platform supported by brackets attached to formwork.

Guardrail system: means a vertical barrier, consisting of, but not limited to, toprails, midrails, and posts, erected to prevent employees from falling off a scaffold platform or walkway to lower levels.

Hoist: means a manual or power-operated mechanical device to raise or lower a suspended scaffold.

Horse scaffold: means a supported scaffold consisting of a platform supported by construction horses (saw horses). Horse scaffolds constructed of metal are sometimes known as trestle scaffolds.

Independent pole scaffold: (see "Double pole scaffold").

Interior hung scaffold: means a suspension scaffold consisting of a platform suspended from the ceiling or roof structure by fixed length supports.

Ladder jack scaffold: means a supported scaffold consisting of a platform resting on brackets attached to ladders.

Ladder stand: means a mobile, fixed-size, self-supporting ladder consisting of a wide flat tread ladder in the form of stairs.

Landing: means a platform at the end of a flight of stairs.

Large area scaffold: means a pole scaffold, tube and coupler scaffold, systems scaffold, or fabricated frame scaffold erected over substantially the entire work area. For example: a scaffold erected over the entire floor area of a room.

Lean-to scaffold: means a supported scaffold which is kept erect by tilting it toward and resting it against a building or structure.

Lifeline: means a component consisting of a flexible line that connects to an anchorage at one end to hang vertically (vertical lifeline), or that connects to anchorages at both ends to stretch horizontally (horizontal lifeline), and which serves as a means for connecting other components of a personal fall arrest system to the anchorage.

Lower levels: means areas below the level where the employee is located and to which an employee can fall. Such areas include, but are not limited to, ground levels, floors, roofs, ramps, runways, excavations, pits, tanks, materials, water, and equipment.

Masons' adjustable supported scaffold: (see "Self-contained adjustable scaffold").

Masons' multi-point adjustable suspension scaffold: means a continuous run suspension scaffold designed and used for masonry operations.

Maximum intended load: means the total load of all persons, equipment, tools, materials, transmitted loads, and other loads reasonably anticipated to be applied to a scaffold or scaffold component at any one time.

Mobile scaffold: means a powered or unpowered, portable, caster or wheel-mounted supported scaffold.

Multi-level suspended scaffold: means a two-point or multi-point adjustable suspension scaffold with a series of platforms at various levels resting on common stirrups.

Multi-point adjustable suspension scaffold: means a suspension scaffold consisting of a platform(s) which is suspended by more than two ropes from overhead supports and equipped with means to raise and lower the platform to desired work levels. Such scaffolds include chimney hoists.

Needle beam scaffold: means a platform suspended from needle beams.

Open sides and ends: means the edges of a platform that are more than 14 inches (36 cm) away horizontally from a sturdy, continuous, vertical surface (such as a building wall) or a sturdy, continuous horizontal surface (such as a floor), or a point of access. Exception: For plastering and lathing operations the horizontal threshold distance is 18 inches (46 cm).

Outrigger: means the structural member of a supported scaffold used to increase the base width of a scaffold in order to provide support for and increased stability of the scaffold.

Outrigger beam (Thrustout): means the structural member of a suspension scaffold or outrigger scaffold which provides support for the scaffold by extending the scaffold point of attachment to a point out and away from the structure or building.

Outrigger scaffold: means a supported scaffold consisting of a platform resting on outrigger beams (thrustouts) projecting beyond the wall or face of the building or structure, the inboard ends of which are secured inside the building or structure.

Overhand bricklaying: means the process of laying bricks and masonry units such that the surface of the wall to be jointed is on the opposite side of the wall from the mason, requiring the mason to lean over the wall to complete the work. It includes mason tending and electrical installation incorporated into the brick wall during the overhand bricklaying process.

Personal fall arrest system: means a system used to arrest an employee's fall. It consists of an anchorage, connectors, a body belt or body harness and may include a lanyard, deceleration device, lifeline, or combinations of these.

Platform: means a work surface elevated above lower levels. Platforms can be constructed using individual wood planks, fabricated planks, fabricated decks, and fabricated platforms.

Pole scaffold: (see definitions for "Single-pole scaffold" and "Double (independent) pole scaffold").

Power operated hoist: means a hoist which is powered by other than human energy.

Pump jack scaffold: means a supported scaffold consisting of a platform supported by vertical poles and movable support brackets.

Qualified: means one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated his/her ability to solve or resolve problems related to the subject matter, the work, or the project.

Rated load: means the manufacturer's specified maximum load to be lifted by a hoist or to be applied to a scaffold or scaffold component.

Repair bracket scaffold: means a supported scaffold consisting of a platform supported by brackets which are secured in place around the circumference or perimeter of a chimney, stack, tank or other supporting structure by one or more wire ropes placed around the supporting structure.

Roof bracket scaffold: means a rooftop supported scaffold consisting of a platform resting on angular-shaped supports.

Runner (ledger or ribbon): means the lengthwise horizontal spacing or bracing member which may support the bearers.

Scaffold: means any temporary elevated platform (supported or suspended) and its supporting structure (including points of anchorage), used for supporting employees or materials or both.

Self-contained adjustable scaffold: means a combination supported and suspension scaffold consisting of an adjustable platform(s) mounted on an independent supporting frame(s) not a part of the object being worked on, and which is equipped with a means to permit the raising and lowering of the platform(s). Such systems include rolling roof rigs, rolling outrigger systems, and some masons' adjustable supported scaffolds.

Shore scaffold: means a supported scaffold which is placed against a building or structure and held in place with props.

Single-point adjustable suspension scaffold: means a suspension scaffold consisting of a platform suspended by one rope from an overhead support and equipped with means to permit the movement of the platform to desired work levels.

Single-pole scaffold: means a supported scaffold consisting of a platform(s) resting on bearers, the outside ends of which are supported on runners secured to a single row of posts or uprights, and the inner ends of which are supported on or in a structure or building wall.

Stair tower (Scaffold stairway/tower): means a tower comprised of scaffold components and which contains internal stairway units and rest platforms. These towers are used to provide access to scaffold platforms and other elevated points such as floors and roofs.

Stall load: means the load at which the prime-mover of a power-operated hoist stalls or the power to the prime-mover is automatically disconnected.

Step, platform, and trestle ladder scaffold: means a platform resting directly on the rungs of step ladders or trestle ladders.

Stilts: means a pair of poles or similar supports with raised footrests, used to permit walking above the ground or working surface.

Stonesetters' multi-point adjustable suspension scaffold: means a continuous run suspension scaffold designed and used for stonesetters' operations.

Supported scaffold: means one or more platforms supported by outrigger beams, brackets, poles, legs, uprights, posts, frames, or similar rigid support.

Suspension scaffold: means one or more platforms suspended by ropes or other non-rigid means from an overhead structure(s).

System scaffold: means a scaffold consisting of posts with fixed connection points that accept runners, bearers, and diagonals that can be interconnected at predetermined levels.

Tank builders' scaffold: means a supported scaffold consisting of a platform resting on brackets that are either directly attached to a cylindrical tank or attached to devices that are attached to such a tank.

Top plate bracket scaffold: means a scaffold supported by brackets that hook over or are attached to the top of a wall. This type of scaffold is similar to carpenters' bracket scaffolds and form scaffolds and is used in residential construction for setting trusses.

Tube and coupler scaffold: means a supported or suspended scaffold consisting of a platform(s) supported by tubing, erected with coupling devices connecting uprights, braces, bearers, and runners.

Basic Scaffolding Showing all Parts

Bracing 

Tubular welded frame scaffold:  See "Fabricated frame scaffold"

Two-point suspension scaffold (swing stage): means a suspension scaffold consisting of a platform supported by hangers (stirrups) suspended by two ropes from overhead supports and equipped with means to permit the raising and lowering of the platform to desired work levels.

Unstable objects: means items whose strength, configuration, or lack of stability may allow them to become dislocated and shift and therefore may not properly support the loads imposed on them. Unstable objects do not constitute a safe base support for scaffolds, platforms, or employees. Examples include, but are not limited to, barrels, boxes, loose brick, and concrete blocks.

Vertical pickup: means a rope used to support the horizontal rope in catenary scaffolds.

Walkway: means a portion of a scaffold platform used only for access and not as a work level.

Window jack scaffold: means a platform resting on a bracket or jack which projects through a window opening.

Work Site Safety Inspection - Part 7

Work Site Safety Inspection


36. Stairs and stairways

• Are standard stair rails and handrails present on all stairways having four or more risers?
• Are all stairways at least 22 inches wide?
• Do stairs have at least 6.5 feet of overhead clearance?
• Do stairs angle no more than 50 degrees and no less than 30 degrees?
• Are risers on stair steps uniform, with no riser more than 9.5 inches?
• Are steps on stairs and stairways provided with a slip-resistant surface?
• Are stairway handrails 30-42 inches above the leading edge of stair treads?
• Do stairway handrails have at least three inches’ clearance between the handrail and the surface they are mounted on?
• Are stairway handrails capable of withstanding a load of 200 pounds applied in any direction?
• Where stairs or stairways exit directly into an area where vehicles may be operated, have you provided adequate barriers and warnings to prevent employees from stepping into traffic?

37. Tools and equipment:

37.1 Hand tools

• Are all company- and employee-owned tools and equipment in good working condition?
• Are hand tools such as chisels or punches that develop mushroomed heads reconditioned or replaced as necessary?
• Are broken or fractured handles on hammers, axes, or similar equipment replaced promptly?
• Are appropriate handles used on files and similar tools?
• Do employees use appropriate safety glasses, face shields, and similar equipment when using hand tools or equipment that might produce flying materials or be subject to breakage?
• Are jacks checked periodically to ensure they are in good operating condition?
• Are tool handles wedged tightly in the heads of all tools?
• Are tool-cutting edges kept sharp tools will smoothly without binding or skipping?
• Do employees use eye and face protection when they drive hardened or tempered tools, bits, or nails?

37.2 Portable power-operated

• Do grinders, saws, and similar equipment have appropriate safety guards?
• Are power tools used with the shield or guard that the manufacturer recommends?
• Are portable circular saws equipped with guards above and below the base shoe?
• Are circular saw guards checked to ensure guarding of the lower blade portion?
• Are rotating or moving parts of equipment guarded to prevent physical contact?
• Are all cord-connected, electrically-operated tools and equipment either grounded or of the approved double-insulated type?
• Are effective guards in place over belts, pulleys, chains, and sprockets on equipment such as concrete mixers, air compressors, and the like?
• Are portable fans provided with full guards having openings of 1⁄2 inch or less?
• Is hoisting equipment available and used for lifting heavy objects, and are hoist ratings and characteristics appropriate for the task?
• Are ground-fault circuit interrupters (on all temporary electrical 15-, 20-, and 30-ampere circuits) used during periods of construction?

 Or

• Is there an assured equipment-grounding conductor program in place during periods of construction?
• Are pneumatic and hydraulic hoses on power-operated tools checked regularly for deterioration or damage?

38. TRAINING

• Do new employees receive HSE orientation and training prior to exposure to hazards?
• Do employees complete required HSE on-site and online HSE training
• Are weekly safety meetings conducted consistently?
• Are HSE briefings conducted immediately after nears miss incidents and injury accidents?
• Is the on-site Safety Representative involved in safety orientation and training.
• Are safety meetings and other forms of HSE instruction documented with attendance rosters?
• Are employees trained on performing hazardous task certified as competent/qualified?

39. Transportation: employees and materials

• Do employees who operate vehicles on public thoroughfares have operator licenses?
• Are motor vehicle drivers trained in defensive driving and proper use of the vehicle?
• Are employees required to use seatbelts?
• Does each van, bus, or truck used to transport employees have an adequate number of seats?
• When employees are transported by truck, are safeguards provided to prevent them from falling from the vehicle?
• Are vehicles equipped with lamps, brakes, horns, mirrors, windshields, and turn signals that are in good repair?
• Are transport vehicles equipped with handrails, steps, stirrups, or similar devices so employees can safely mount or dismount?
• Is a fully-charged fire extinguisher, in good condition maintained in each employee transport vehicle?
• When sharp-edged cutting tools are carried in passenger compartments of employee transport vehicles, are they placed in closed boxes or containers that are secured in place?
• Are employees prohibited from riding on top of any load that can shift, topple, or otherwise become unstable?
• Are materials that could shift and enter the cab secured or barricaded?

40. Ventilation for indoor air quality

• Does the HVAC system provide at least the quantity of outdoor air designed into the system at the time the building was constructed?
• Is the HVAC system inspected at least annually and maintained so that it is clean and efficient?
• Are efforts made to purchase furnishings or building treatments that do not give off toxic or offensive vapors?
• Are indoor air quality complaints investigated, and are the results conveyed to workers?

41. Walkways(For construction and operation process)

• Are aisles and passageways kept clear and at least 22 inches wide?
• Are aisles and walkways appropriately marked?
• Are wet surfaces covered with non-slip materials?
• Are openings or holes in the floors or other walking surfaces repaired or otherwise made safe?
• Is there a safe clearance for walking in aisles in which vehicles operate?
• Are materials and equipment stored so sharp objects do not obstruct the walkway?
• Are changes of direction or elevation easily identified?
• Do aisles or walkways near moving or operating machinery, welding, and similar operations keep employees away from hazards?
• Is there floor-to-headroom height of at least 6.5 feet provided for the entire length of any walkway?
• Are standard guardrails provided wherever aisle or walkway surfaces are elevated more than four feet above floor or ground?
• Are bridges provided over conveyors and similar hazards?

42. WASTE AND WASTE WATER

• Is the waste collected and stored correctly?
• Is the waste separated correctly? (containers labeled, incompatible substances separated, etc.)
• Has the municipality granted any exemptions regarding waste, and are they still valid?
• Which types of waste water does the site have (sanitary waste water, process waste water)?
• Are there any requirements regarding measurements of waste water, and if requirements are set – are the measurements carried out?

43. Welding, cutting and brazing

• Do you allow only authorized and trained personnel to use welding, cutting, or brazing equipment?
• Are compressed gas cylinders regularly examined for signs of defect, deep rusting, or leakage?
• Are cylinders kept away from sources of heat?
• Are employees prohibited from using cylinders as rollers or supports?
• Are empty cylinders appropriately marked, their valves closed, and valve-protection caps placed on them?
• Are signs posted that read “DANGER — NO SMOKING, MATCHES, OR OPEN LIGHTS,” or the equivalent?
• Are cylinders, cylinder valves, couplings, regulators, hoses, and apparatus kept free of oily or greasy substances?
• Unless secured on special trucks, are regulators removed and valve-protection caps put in place before moving cylinders?
• Do cylinders without fixed hand wheels have keys, handles, or nonadjustable wrenches on stem valves when in service?
• Are liquefied gases stored and shipped with the valve end up and with valve covers in place?
• Before a regulator is removed, is the valve closed and gas then released from the regulator?
• Is open circuit (no load) voltage of arc welding and cutting machines as low as possible and not more than the recommended limit?
• Are electrodes removed from holders when not in use?
• Are employees required to shut off the electric power to the welder when no one is using it?
• Is suitable fire-extinguishing equipment available for immediate use?
• Are welders forbidden to coil or loop welding electrode cable around their bodies?
• Is work and electrode lead cable frequently inspected for wear and damage and replaced when needed?
• Do the means for connecting cable lengths have adequate insulation?
• When the object to be welded cannot be moved and fire hazards cannot be removed, are shields used to confine heat, slag, and sparks?
• Are fire watchers assigned when welding or cutting is performed in locations where a fire might develop?
• When welding is done on metal walls, are precautions taken to protect combustibles on the other side?
• Before hot work begins, are drums, barrels, tanks, and other containers thoroughly cleaned and tested so that no substances remain that could explode, ignite, or produce toxic vapors?
• Do eye-protection helmets, hand shields, and goggles meet appropriate standards?
• Do employees use appropriate PPE when exposed to the hazards of welding, cutting, or brazing operations?
• Do you check for adequate ventilation where welding or cutting is performed?
• When welders work in confined spaces is the atmosphere monitored and is there a means for their quick evacuation in an emergency?
• Are regulator-pressure adjusting screws released when welding or cutting is stopped for an extended period of time?

44. Work environment: general

• Are all work areas clean and orderly?
• Are walking surfaces dry or slip-resistant?
• Are spilled materials or liquids cleaned up immediately?
• Is combustible scrap, debris, and waste safely contained and removed from the site promptly?
• Are covered metal waste cans used for oily and paint-soaked waste?
• Is the appropriate number of toilets and washing facilities provided?
• Are toilets and washing facilities sanitary?
• Are work areas adequately lighted?

Work Site Safety Inspection - Part 6

Work Site Safety Inspection

28. Medical services and first aid

• Have you developed an emergency medical plan?
• Are emergency phone numbers posted?
• Are first-aid kits with necessary supplies easily accessible to each work area, periodically inspected, and replenished as needed?
• Are means provided for quick drenching or flushing of the eyes and body in areas where caustic or corrosive liquids or materials are handled?

29. Noise: hearing conservation

• Are there areas in your workplace where continuous noise levels exceed 85 dBA?
• Are noise levels measured using a sound-level meter or an octave band analyzer, and are you keeping records of these levels?
• Have you tried isolating noisy machinery from the rest of your operation?
• Have engineering controls been used to reduce excessive noise?
• Where engineering controls are not feasible, are administrative controls used to minimize employee exposure to noise?
• Is there a preventive health program that educates employees about safe levels of noise and exposure, effects of noise on their health, and use of personal protection?
• Are employees who are exposed to continuous noise above 85 dBA retrained annually?
• Have you identified and posted work areas in which noise levels make voice communication difficult?
• Does every employee working in areas where noise levels exceed 90 dBA use approved hearing protection equipment (noise attenuating devices)?
• Are employees properly fitted and instructed in the proper use and care of hearing protection?
• Are employees who are exposed to continuous noise above 85 dBA given periodic audiometric testing to ensure that you have an effective hearing-protection system?

30. Personal protective equipment (PPE)

• Have you assessed workplace hazards that might require PPE and reviewed related injuries?
• Has the assessment been documented?
• Does the documentation identify the workplace evaluated?
• Has training been provided to each employee who is required to wear PPE?
• Has the training been documented?
• Are protective goggles or face shields provided to employees and worn when there may be danger of flying material or caustic or corrosive materials?
• Are ANSI-approved safety glasses (or safety goggles of relevant standard as per site rules) worn at all times in areas where there is risk of eye injury?
• Are protective gloves, aprons, or shields provided to employees for protection against cuts, corrosive liquids, and chemicals?
• Are hardhats provided and worn where there is a danger of falling objects?
• Are hardhats inspected periodically for damage to the shell and the suspension system?
• Do employees exposed to vehicular traffic wear high visibility garments that make them stand out from their surroundings?
• Do workers wear reflective garments at night?
• Are appropriate respirators provided for regular or emergency use where they are necessary?
• Is there a written respirator program?
• Are the respirators inspected before and after each use?
• Is a written record kept of all inspection dates and findings?
• Have all employees been trained in work procedures, and proper use and maintenance of protective clothing and equipment for cleaning up spilled toxic or other hazardous materials or liquids?
• Is a spill kit available for employees to clean up spilled toxic or hazardous materials?
• Are employees required to wear safety shoes when they are exposed to conditions that could cause foot injuries?
• Is all protective equipment sanitary and ready to use?
• Is there an eyewash facility and a quick-drench shower in each work area where employees are exposed to caustic or corrosive materials?
• Do employees have lunch areas in areas where there is no exposure to toxic materials?
• Is protection from occupational noise provided when sound levels exceed those of the hearing conservation standards?

31. Piping systems: identification (for both construction and operation process)

• When non potable water is piped through a facility, are outlets or taps posted to alert employees that the water is unsafe and not to be used for drinking, washing, or personal use?
• Is each pipeline identified when hazardous substances are transported through above ground piping?
• Have asbestos-covered pipelines been identified?
• When pipelines are identified by colored paint, are all visible parts of the line well identified?
• When pipelines are identified by colored bands or tape, are they identified at reasonable intervals, and at each outlet, valve, or connection?
• When pipelines are identified by color, is a color code posted in on the pipeline where employees are likely to need it and could be confused by the hazards?
• When the contents of pipelines are identified by name or by abbreviation, is the information readily visible on the pipe near each valve or outlet?
• When tags identify pipelines carrying hazardous substances, are the tags constructed of durable material, the message clearly and permanently distinguishable, and tags installed at each valve or outlet?
• When electricity, steam, or other external sources heat pipelines, are suitable warning signs or tags placed at unions, valves, or other serviceable parts of the system?

32. Psychosocial Environment

• Is it necessary that the employees work very quickly?
• Do employees have only a little influence on the amount of work?
• Do employees have only a little influence on the performance of the work?
• Is the work repetitious / tedious?
• Do employees regularly work outside normal working hours e.g. swing or night shift?
• Do employees often have to work overtime?
• Do employees often not accomplish the set tasks?
• Are employees feel uncomfortable reporting injuries, hazards, or concerns?

33. Recognition

• Are employees recognized for consistent excellent performance?
• Do employees receive recognition and reward for making suggestions?
• Do employees receive tangible rewards for suggestions that add value to the success of the company?
• Do employees receive recognition for voluntary participation in safety teams and activities?
• Are employees submitted for formal recognition/rewards when they meet the criteria?

34. Recordkeeping (For both construction and operation purposes)

• Are all occupational injuries and illnesses, including those involving loss of life, loss of consciousness, loss of time from work, and those requiring treatment other than first aid, recorded as required? 
• Are copies of kept for five years (as per legal requirement)? 
• Are employee’s medical records and records of exposure to hazardous substances or harmful physical agents current?
• Have arrangements been made to maintain required records for the legal period for each type of record? 
• Are operating permits and records current for elevators, pressure vessels, and liquefied petroleum gas tanks?
• Are employee safety and health training records maintained?
• Are safety inspections and corrections documented and maintained?

35. RAW MATERIALS

• Are substances and materials stored appropriately and according to the regulations? (remember fire hazard)
• Can spills or leaks of chemical substances reach any navigable waters or municipal sewers?
• Are environmental accident response materials (spill kits, absorbents, dams, etc.) readily and conspicuously available?

                                               ------ Continued in next post

                                                          work site safety inspection part 7

Work Site Safety Inspection - Part 5

Work Site Safety Inspection

24. Ladders: portable

• Are all ladders in good condition, joints between steps and side rails tight, all hardware and fittings securely attached, and movable parts operating freely without binding or undue play?
• Are there non-slip safety feet on all ladders except step ladders?
• Are ladder rungs and steps free of grease and oil?
• Are employees prohibited from placing a ladder in front of doors opening toward the ladder except when the door is blocked open, locked, or guarded?
• Are employees prohibited from placing ladders on boxes, barrels, or other unstable bases?
• Are employees instructed to face the ladder when ascending and descending?
• Are employees prohibited from using ladders that are broken, missing steps, rungs, cleats, broken side rails, or other faulty parts?
• Are employees instructed not to use the top step of ordinary stepladders as a step?
• When portable rung ladders are used to gain access to elevated platforms, roofs, and the like, does the ladder always extend at least three feet above the elevated surface?
• Do you require the users of portable rung or cleat-type ladders to place the base so that slipping will not occur or to lash or otherwise hold the ladder in place?
• Do portable metal ladders have legible signs reading “CAUTION — Do Not Use Around Electrical Equipment” or equivalent wording?
• Are the rungs of ladders uniformly spaced at 12 inches, center to center?

25. Lockout and tagout

• Is all machinery or equipment capable of movement de-energized or disengaged and locked out during cleaning, servicing, adjusting, or setup?
• Do you prohibit locking out control circuits instead of locking out main power disconnects?
• Are all control valve handles provided with a means of lockout?
• Does the lockout/tagout procedure require that stored (potential) energy be released or blocked before equipment is locked-out for repairs?
• Are appropriate employees provided with individually keyed personal safety locks?
• Are employees required to maintain control of their keys while they have safety locks in use?
• Do you require employees to check the safety of the lockout by attempting to start up after making sure no one is exposed?

When the power-disconnecting means does not also disconnect the electrical control circuit:

• Are appropriate electrical enclosures identified?
• Are means provided to ensure the control circuit can also be disconnected and locked out?

26. Machine guarding

• Is there an employee training program for safe methods of machine operation?
• Is there adequate supervision to ensure that employees follow safe machine operating procedures?
• Is there a regular program of safety inspection for machinery and equipment?
• Is all machinery and equipment clean and properly maintained?
• Is sufficient clearance provided around and between machines to allow for safe operation, setup, servicing, material handling, and waste removal?
• Is equipment and machinery securely placed and anchored when necessary to prevent tipping or other movement that could result in personal injury?
• Is there a power shutoff switch within reach of the operator’s position at each machine?
• Are the noncurrent-carrying metal parts of electrically-operated machines bonded and grounded?
• Are foot-operated switches guarded or arranged to prevent accidental actuation by personnel or falling objects?
• Are manually operated valves and switches that control the operation of equipment and machines clearly identified and readily accessible?
• Are all emergency stop buttons colored red?
• Are all pulleys and belts (within seven feet of the floor or working level) properly guarded?
• Are all moving chains and gears properly guarded?
• Are methods provided to protect the operator and other employees in the machine area from hazards created at the point of operation, ingoing nip points, rotating parts, flying chips, and sparks?
• Are machinery guards secured and arranged so they do not present a hazard in their use?
• If special hand tools are used for placing and removing material, do they protect the operator’s hands?
• Are revolving drums, barrels, and containers that are required to be guarded by an enclosure that is interlocked with the drive mechanism so that revolution cannot occur,so guarded?
• Do arbors and mandrels have firm and secure bearings, and are they free from play?
• Are provisions made to prevent machines from automatically starting when power is restored following a power failure or shut-down?
• Are machines constructed to be free from excessive vibration when the largest size tool is mounted and run at full speed?
• If machinery is cleaned with compressed air, is air pressure controlled and personal protective equipment or other safeguards used to protect operators and other workers from eye and body injury?
• Are fan blades protected with a guard having openings no larger than 1⁄2 inch when operating within seven feet of the floor?
• Do saws used for ripping have anti-kickback devices and spreaders?
• Are radial arm saws guarded and so arranged that the cutting head will gently return to the back of the table when released?

27. Materials handling

• Are materials stored so that they prevent sprains or strains when employees retrieve them?
• Is there a safe clearance for moving equipment through aisles and doorways?
• Are aisles permanently marked and kept clear to allow safe passage?
• Are motorized vehicles and mechanized equipment inspected daily or before use?
• Are vehicles shut off and brakes set before loading and unloading?
• Are containers of combustibles or flammables properly stacked and stabilized when they are being moved?
• Are trucks and trailers secured from movement during loading and unloading?
• Are dock boards (dock plates) used during loading and unloading operations?
• Are dock plates and loading ramps adequately constructed and maintained to support imposed loads?
• Are hand trucks maintained in safe operating condition?
• Are chutes equipped with side boards of sufficient height to prevent materials from falling off?
• Are chutes and gravity-roller sections firmly placed or secured to prevent displacement?
• At the delivery end of rollers or chutes, are provisions made to brake the movement of materials?
• Are materials handled at a uniform level to prevent lifting or twisting injuries?
• Are material-handling aids used to lift or transfer heavy or awkward objects?
• Are pallets usually inspected before loading or moving them?
• Do you use hooks with safety latches or other devices when hoisting materials, so that slings or load attachments cannot accidentally slip off the hoist hooks?
• Are securing chains, ropes, chokers, or slings adequate for the job?
• When equipment or materials are being hoisted, do you ensure that no one will be passing under the suspended loads?

                                               ------ Continued in next post

                                                          work site safety inspection part 6