Matrix Technologies Inc., A Better Process for Success.
Proper design technique is not solely the work of talented individuals. For each project, the design team needs to be aware of the veritable “alphabet soup” of codes and regulations that govern and provide guidance in the safe implementation of the project. A sampling of the more common acronyms follows:
OSHA – The Occupational Safety and Health Administration plays a huge role in the design of new systems. OSHA guidelines govern such things as handrail height, ladder and platform design, noise limitations, and traffic flow.
PSM – Process Safety Management is defined in 29 CFR 1910 and is part of the OSHA guidelines. PSM requires process owners to maintain the Process Safety Information (PSI) such as Piping and Instrument Diagrams (P&IDs) and Material Safety Data Sheets (MSDS) in up to date form. PSM also requires a Process Hazard Analysis (PHA) of new systems and requires owners to follow a Management of Change (MOC) procedure when implementing modifications to existing systems.
(Getting tired of acronyms, yet?)
ASME – The American Society of Mechanical Engineers has developed numerous codes that govern the design of pressure vessels, process piping, steam boilers, and the majority of other mechanical equipment.
API – The American Petroleum Institute also provides design guidance for engineered systems to be installed in oil refineries and other petrochemical facilities. The API codes take into account the specialized requirements of petroleum processing.
NFPA – The National Fire Protection Association provide regulations and guidelines for the proper design of fire protection systems, buildings, and electrical safety.
ANSI / HI – The American National Standards Institute provides consensus standards for nearly every sector of industry. The Hydraulic Institute is focused on pumps and pumping systems. The combined ANSI / HI standards provide the framework for proper pump and piping design.
WRC – The Welding Research Council provides the latest technology and best practices for welding. The WRC also provides methods for calculating the strength of welds and vessel nozzles.
PFI – The Pipe Fabrication Institute provides industry best practices for the layout and installation of process piping systems.
3A Sanitary – In food grade applications, the 3A Sanitary standards by the International Association for Food Protection (IAFP) represent criteria for cleanability of dairy, egg, and food processing equipment.
ASHRAE – The American Society of Heating, Refrigerating, and Air-Conditioning Engineers guidelines are followed for the proper design of ventilation systems, both in process applications and space conditioning applications.
AGA – The American Gas Association has developed guidelines for the safe design, installation, and handling of natural gas.
And we have not addressed two of the most important factors to a successful project: Satisfying the Environmental Protection Agency (EPA) by obtaining the necessary permits and following the International Building Code (IBC) to ensure new structures are properly designed!
The codes and regulations capture the combined knowledge of past design successes and failures to ensure new designs are engineered to operate as safely as possible. Owners can count on professional engineering firms like Matrix Technologies, Inc. to guide their projects through the “alphabet soup” of standards to successful operation.
Contact Matrix Technologies with all your Process Design Regulatory Compliance needs!
Before implementing Tracking and Tracing (T&T) solution, there are several aspects that should be considered, beyond the typical regulatory needs.
With the recent increase in product recalls and their coverage in the media, it is increasingly important for manufacturers to evaluate every aspect of manufacturing to ensure safe and high quality products. Product safety and security is a major concern for all manufacturers, since a product recall can seriously impact the bottom line, and affect their existence The entire supply chain is closely being monitored and information gathered at every point to perform a thorough analysis.
In the food and beverage industry, HACCP programs have been rolled out along with extensive effort to minimize human contact with the final product. A number of regulations like Bio-Terrorism Act of 2002 have been put in place and more are expected in the future. The regulations are forcing the manufacturers to maintain records that will enable a quick and efficient recall of products that are off-spec or harmful to consumers. Paper-based record keeping is very inefficient and prone to manual entry errors. An automated regulatory data management system is becoming a necessity that can help in tracking and tracing material and resources that are used during manufacturing quickly and consistently.
A T&T solution tracks the equipment used, the materials consumed, the operators involved, and the utilities used to manufacture a particular product. It provides the ability to perform quick product recalls based on customer feedback or raw material quality. Tainted products can be identified quickly and accurately so that they can be recalled. Proper record keeping enables focused recalls with limited scope, thereby reducing lost production and saving millions of dollars on a single recall.
Most T&T solutions are implemented by manufacturers out of necessity to be compliant with regulations, a well-thought out implementation can also provide a strategic advantage to the manufacturer. T&T solutions can be extended beyond Regulatory Data management to additional areas of Recipe Management, Asset Utilization and Continuous Improvement programs which all provide improved quality, cost reduction and consistency in the process.
With the increased focus on sustainability and “green” manufacturing, it has become exceedingly critical to track material and energy usage. Material and energy balances need to be maintained throughout the manufacturing process. These help in calculating the production efficiency and get a better understanding of the performance. Processes where scrap/waste is being generated or energy wasted can be easily identified.
Successfully implemented T&T solutions can provide a number of strategic advantages that have direct impact on the bottom-line
• Good record keeping and regulatory compliance
• Visibility across entire supply chain
• Accurate WIP and inventory
• Good quality products
T&T solutions can provide a number of benefits, beyond the obvious regulatory needs. Companies should consider all the positive aspects of these systems as they justify their implementation.
Do you currently have a NFPA 70E arc flash program in place? If you do or if you are finally getting to it, here is a peek at the top seven changes coming your way for the new NFPA 70E -2012 edition.
Change #1 -
The 2012 edition of NFPA 70E will use the term “arc-rated” or “AR” before any reference to “flame-resistant” or “FR.” The term “arc-rated” refers to a material property or attribute in terms of a material’s performance when exposed to an electric arc. The personal protective equipment (PPE) label that only displays FR without indication of AR will no longer be allowed to help the employee achieve the appropriate level of PPE.
Change #2 –
Due to many plants utilizing contract personnel, NFPA 70E-2012 will require a documented meeting between the host employer and the contract employer. We believe that this is designed to align the safety procedures of both entities and make both companies aware of each other’s intentions for the work to be performed.
Change #3 -
The employer shall determine, through regular supervision or through inspections conducted on at least an annual basis that each employee is complying with the safety-related work practices required by the NFPA 70E standard. This compliance screening requirement currently does not exist in the 2009 standard.
Change #4 -
Retraining of qualified and unqualified personnel shall be performed at intervals not to exceed 3 years. Basically, the employer needs to document and recertify the qualified employees every three years and also needs to conduct electrical safety awareness training for unqualified employees at that same interval.
Change #5-
An arc rated balaclava shall be used with an arc rated face shield when the back of the head is within the Arc Flash Boundary. An arc rated hood shall be permitted to be used instead of an arc rated face shield and balaclava. Also, an arc rated hood shall be used when the anticipated incident energy exposure exceeds 12 calories/cm2.
Change #6-
DC is now being addressed in this version of NFPA70E. They have added new Hazard/Risk Category Classifications table for dc equipment similar to former Table 130.7(C)(9) for ac equipment. This table will feature specifications for hazard/risk categories for DC systems. Also related to this change is a new section entitled “DC Arc Flash Calculations”.
Change #7-
Electrical Safety Program: The electrical safety program shall be audited to verify that the principles and procedures of the electrical safety program are in compliance with this standard. The frequency of the audit shall not exceed three years.
There are many other small changes included in this next revision such as removing duplicate items (already in the NEC), reformatting, expanding on existing concepts and other miscellaneous changes. This article picked out the seven top items that will require action by your safety program to be in compliance with NFPA 70E.
Defining Moments Build Character
An ethical decision typically involves choosing between two options -- one we know to be right and another we know to be wrong. But a "defining moment" challenges us in a deeper way by asking us to choose between two or more ideals in which we deeply believe. Such decisions rarely have one correct response. Taken cumulatively over many years, they form the basis of an individual's character.
Defining moments ask managers to dig below the busy surface of their lives and refocus on their core values and principles. Once uncovered, those values and principles renew their sense of purpose at the workplace and act as a springboard for shrewd, pragmatic, politically astute action.
Three types of defining moments are particularly common in today's workplace. The first type is larely an issue of personal identity. It raises the question, Who am I? The second type concerns groups as well as individuals. It raises the question, Who are we? The third kind involves defining a company's role within society. It raises the question, Who is the company?
By learning to identify each of those three situations, managers can learn to successfully make the right decisions. Through this process of self-inquiry, managers can gain the tools to tackle their most challenging and essential business dilemmas.
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