For many employers, maintaining OSHA compliance is a significant concern. OSHA sets stringent standards to ensure workplace safety. Non-compliance can result in severe penalties, costly downtime and, most importantly, endangerment to employee safety. In industries dealing with electrical systems, the risks of arc flashes and electric shocks are ever-present, making compliance with safety standards not just a regulatory necessity, but a critical component of operational integrity.
Employers must proactively seek solutions that enhance safety, streamline compliance and improve efficiency to stay ahead. Equipping employees with the right tools and technologies is paramount in mitigating risks and ensuring that safety protocols are effective and practical. This is where innovative and exciting solutions like Grace Technologies’ Voltage Test Station (VTS) and ChekVolt come into play.
Meet the hero
Torrance Casting Inc., a state-of-the-art metal casting facility in La Crosse, Wis., embarked on a quest to enhance its Lockout/Tagout (LOTO) procedures. While effective, the existing methods used were time-consuming and posed significant risks. The stakes weren’t just high, they were critical for maintaining compliance with stringent safety regulations, minimizing downtime and protecting the workforce from electrical hazards.
Unique to Torrance Casting’s environment is a furnace connected to a medium voltage transformer, directly operating at 575 V. Upon analyzing the safety concerns for the company’s workers operating within this cabinet, the team at Torrance Casting enlisted the help of ASG Electric to devise a safer solution.
ASG Electric conducted an arc flash calculation, which revealed a high incident energy of 119 calories. This led Torrance Casting to investigate devices that test for the absence of voltage to ensure workers could confirm an electrically safe work condition before interacting with the cabinet. The company turned to Grace Technologies’ VTS.
The need for safe solutions enabled by voltage testing devices isn’t unique to Torrance Casting, however. Most, if not all, metal fabrication shops employ some type of equipment that could pose a safety threat to employees, especially those that perform maintenance functions or carry out tool changes.
Grace Technologies presented the VTS as a viable solution for Torrance Casting. The VTS combines a voltage indicator and a safe test point within a single housing, making electrical safety simple by allowing users to perform LOTO procedures and test for the absence of voltage without opening the cabinet door. This reduces exposure to high incident energy, ensuring safety and compliance with National Fire Protection Association (NFPA) 70E standards.
LED lights with a built-in voltage indicator illuminate the verification of voltage presence while the safe test point allows users to test for the absence of voltage with trusted metered devices. Torrance Casting successfully integrated the VTS, eliminating workers’ exposure by bringing true testing to the cabinet’s front door.
Understanding the risks
Due to its operations, the metals manufacturing industry is one of the most hazardous sectors. Workers in this industry are routinely exposed to various risks, including electrical injuries and arc flashes during significant downtime for maintenance procedures. According to OSHA, the metals manufacturing sector reports high rates of nonfatal injuries and illnesses compared to other industries.
Electrical injuries are particularly concerning. These injuries can range from minor shocks to severe burns and, in some cases, they can be fatal. For example, an arc flash is an electrical explosion or discharge resulting from a low-impedance connection to the ground or another voltage phase in an electrical system. The intense heat and energy released during an arc flash can cause severe burns, blindness and even death. The NFPA estimates 2,000 workers are admitted to burn centers annually for extended injuries caused by arc flash incidents.
Downtime in the metals manufacturing industry is not just a matter of lost production; it also represents significant financial losses and can impact a company’s reputation for reliability. Unplanned downtime can be extremely costly, particularly during maintenance or emergency repairs. Studies have shown that unplanned downtime can cost manufacturers up to $260,000 per hour.
This figure is typically associated with significant manufacturing operations where high-value production and tight schedules mean any interruption can quickly escalate costs. For example, in the automotive industry, downtime can cost up to $3 million per hour. This emphasizes the critical need for efficient and safe maintenance procedures.
Reducing the risks
Incorporating advanced safety devices like the VTS and ChekVolt can significantly mitigate these risks. These permanent electrical safety devices (PESDs) enhance safety and efficiency during maintenance procedures.
The VTS, utilized by Torrance Casting, combines a voltage indicator and a safe test point within a single housing. This allows for the absence of voltage testing without opening electrical enclosures, thereby reducing the exposure to high incident energy and ensuring compliance with NFPA 70E standards. The ChekVolt goes a step further by integrating both functions into one device, providing a streamlined solution for confirming the absence of voltage.
One of the most significant benefits of using the VTS and ChekVolt is reducing LOTO procedure times. Traditional LOTO procedures can be time-consuming and complex, often requiring the opening of electrical cabinets and exposure to potentially live circuits. This increases the risk of electrical injuries and leads to extended downtime.
Research and case studies have shown that incorporating the VTS and ChekVolt can decrease LOTO times by up to 45 min. per procedure. For instance, Torrance Casting reported significant time savings by integrating the VTS into their operations. This efficiency gain translates to reduced downtime and higher productivity, critical in maintaining a competitive edge in the metals manufacturing industry.
All the benefits
While Torrance Casting implemented the VTS, Grace Technologies has also developed the ChekVolt, which builds upon the VTS’s functionality by integrating the voltage indicator and the safe test point into one device. The ChekVolt provides enhanced safety by reducing the risk of electrical hazards and ensuring compliance with OSHA and NFPA 70E standards. Here are the key benefits for both solutions:
- Enhanced safety. The VTS and ChekVolt reduce the risk of electrical hazards by providing clear visual indications of voltage presence and allowing safe testing of voltage absence.
- Compliance. Both devices ensure compliance with OSHA and NFPA 70E standards, making it easier for companies to meet regulatory requirements.
- Efficiency. Both devices significantly reduce downtime by streamlining LOTO procedures, improving overall operational efficiency.
By integrating the VTS into company operations, Torrance Casting achieved remarkable results:
- Time savings. The VTS significantly reduced LOTO procedure times, saving time and minimizing downtime, allowing for faster and safer maintenance operations.
- Compliance and safety. The high impedance-protected test points ensured compliance with OSHA and NFPA 70E requirements. They also enabled safe and efficient absence of voltage testing, preventing accidental contact with live voltage.
- Operational efficiency. Streamlined troubleshooting and maintenance processes, particularly during unplanned maintenance, reduced the need to take entire feeders offline.
Torrance Casting’s integration of the VTS has transformed its LOTO procedures, setting a new standard in electrical safety and operational efficiency. This success story underscores the importance of incorporating innovative electrical safety products like the VTS and ChekVolt into industry-specific operations, including the metals manufacturing sector. Metals manufacturing companies face unique electrical safety challenges, and the VTS and ChekVolt offer practical solutions to ensure compliance and protect workers from electrical hazards.
Grace Technologies remains at the forefront of electrical safety, empowering organizations to achieve a safer, smarter and more productive future. The benefits of the VTS and ChekVolt extend beyond compliance, offering tangible safety and operational efficiency improvements. Following Torrance Casting’s example, employers can significantly enhance compliance, protect employees and improve operational efficiency with innovative solutions like the VTS and ChekVolt.
