Industrial safety is complicated. Installing fixed barriers and / or electrically interlocked guarding around a machine or process seems like a simple concept, but to optimize the process a human operator must interface with a potentially dangerous machine for normal operations and for maintenance activities.
ANCAM Solutions Company Ltd. has developed a very comprehensive approach to industrial safety challenges. Our system includes the following specific steps to ensure the best possible safety solution for each and every situation:
- Risk Assessment: The basis for every industrial safety project is a risk assessment. The risk assessment quantifies the hazards operations and maintenance staff are exposed to and establishes the category of safety that safety systems must be designed to.
- Guard Plan: The guard plan is a graphic layout of the safety system components to allow all stakeholders to visualize the planned systems.
- Functional Description / Philosophy: The functional description provides the written plan, describing how the safety system components shown on the guard plan will work after full safety system integration.
- Safety System Design Drawings: Design drawings are provided for mechanical, electrical and other safety system components. Details for controlling all sources of potential hazardous energy (electrical/pneumatic/hydraulic, gravity, etc.) must be shown in these details to ensure that the fully integrated system is compliant with applicable codes and safe for your staff to operate. Approval of the design drawings marks a milestone in any safety upgrade project; after the designs have been approved the physical work of fabrication, assembly and site installation begins.
- Fabrication / Assembly / Shop Acceptance Testing: Mechanical guarding, electrical safety system components and electrical safety control panels are shop fabricated, assembled and fully wired up. If there is a safety PLC and HMI involved these are fully programmed and configured. Every assembly is then fit up, powered up, and tested for function; if it does not work as designed and intended it does not leave our plant until adjustments or rework allow for a passing shop acceptance test result.
- Site Integration: The site integration of safety system components into an operating facility is difficult and has many variables. Machine access and downtime opportunities for mechanical and electrical system installations and operator training and sign off on revised procedures are two common challenges which must be planned and managed to make the integration process successful.
- System Acceptance Testing: The last and most important step in the industrial safety process is proving that the installed systems function as designed and intended. Redundant systems and system components are proved for failure modes and to baseline the modified system performance. A punchlist tracks outstanding or defective items to ensure that no details are missed during this process.
- Compliance Documentation and Turnover: The risk assessment is the basis for compliance documentation which may include a prestart health and safety review or declaration of conformance written in a manner to address the standard words of government inspectors that “the process/equipment will not likely endanger the health or safety of a worker.” The turnover of the fully upgraded, integrated and proven process is a milestone that ANCAM Associates pride themselves on each and every time – it is very satisfying when this milestone is achieved for all stakeholders on the project.
Our in house staff includes Licensed Professional Electrical/Mechanical Engineers who are available to do Pre-Start Health and Safety Reviews (PSHSR/PSR’s), Technologists, and Designers, Certified Welders, Licensed Electricians and PLC/HMI Programmers to help with any safety integration/upgrade projects to new or older equipment in order to comply with local regulations and CSA Machinery Standards. We work across Ontario and beyond to ensure your operation’s safety.
While this process may seem logical and rudimentary, our experience on industrial safety projects includes cleaning up on many projects where others have failed.