Recently, one of our sockets exploded while loosening a bolt using a HyTorc hydraulic wrench.

No one was injured, but we take these incidents seriously, generating a “Near Miss” report and subsequent corrective action. We discussed exploding sockets in a previous Safety Tip, which you can review in the May 8, 2012 post (see below).

Since that post, we purchased TorcUp sockets for all our tool sets, and sprayed them yellow to make sure they were exclusively used with our HyTorc heads. One of these dedicated sockets broke under load. Please comment (below) on additional steps we can take for our corrective action.  We need your experience and expertise.

Additional information: The broken socket was less than a year old.  It was a 1” drive, 1 5/8” 12 point socket under an 8000 PSI load.  We chose TorcUP sockets as they were the middle of the road in pricing of the three vendors we reviewed (one was HyTorc).

All of us face similar safety concerns in our operations. If you would like one of your concerns discussed in this forum, please contact us via Mr. Turbine (click here) and we will start the conversation in our next newsletter. We will not share your contact info but you can also post anonymously.

Mr. Turbine will be happy to give an immediate response if you request it, but of course we must have your correct contact info.

We’re embarrassed. We had our first recordable accident after 909 days (over 500,000 hours).

Just when everything was going so right. We had the toolbax safety meeting at start of shift to discuss the day’s hazards. We had the Job Safety Analysis for the task to be performed. We had top management buy-in and a dedicated and experienced Safety Director conducting random on-site inspections.

But a mechanic was not wearing gloves when he knew he should have been, and he cut his finger. He may not have a scar on his finger from the incident, but the permanent scar on his soul gives evidence of the depth of the safety culture at TGM.

And we still had an accident. Take heed from our mistake:

Hands are hurt more often than any other part of the body. Your hands are your wage-earners. As talented as your hands are, they can’t think; they are your servants, and it is up to you to think and keep them out of trouble.

Be sure you wear the right kind of gloves for the particular kind of work you are doing. When you wear gloves, you aren’t trusting to luck and you’re not taking unnecessary chances.

Wear gloves when you are doing a job that needs them, but not around moving machinery. Time spent in preparing your hands for the job will not only save trouble for you but will probably save time in doing the job.

Refer to your SDS (MSDS) sheets for gloves required for use with certain chemicals.

A confined space does not necessarily mean a small, enclosed space. It could be rather large, such as a ship’s hold, a fuel tank, or a pit.

One of the first defining features of a confined space is it’s large enough to allow an employee to enter and perform work. The second defining feature is it has limited means of entry or exit. Entry may be obtained through small or large openings and usually there is only one way in and out. The third defining feature is that confined spaces are not used for continuous or routine work.

All confined spaces are categorized into two main groups: non-permit and permit-required. Permit-required confined spaces must have signs posted outside stating that entry requires a permit.

In general, confined spaces contain serious health and safety threats including:

• Oxygen-deficient atmospheres
• Flammable atmospheres
• Toxic atmospheres
• Mechanical or physical hazards
• Loose materials that can engulf or smother

Although a confined space is obviously dangerous, the type of danger is often hidden. For example, a confined space with sufficient oxygen might become an oxygen-deficient space once a worker begins welding or performing other tasks.

These are some of the reasons confined spaces are hazardous:

• Lack of adequate ventilation can cause the atmosphere to become life threatening because of harmful gases.

• The oxygen content of the air can drop below the level required for human life.

• Sometimes a confined space is deliberately filled with nitrogen as a fire prevention technique. Nitrogen cannot sustain human life, so you must use respiratory protection.

• Many gases are explosive and can be set off by a spark.

• Even dust is an explosion hazard in a confined space. Finely-ground materials such as grain, fibers and plastics can explode upon ignition.

• Confined spaces often have physical hazards, such as moving equipment and machinery.

• Tanks and other enclosed confined spaces can suddenly be filled with materials unless the flow process for filling it is controlled.

Remember, before entering any confined space, you must test the atmosphere to determine if any harmful gases are present. There must also be radio contact with an attendant outside the confined space and a rescue team at the ready in case of an emergency.

Winter is definitely here across the U.S.

Here are some points on surviving the cold that you can tailor to the particular circumstances of your workplace:

Winter Driving

• Keep in mind that while black ice can form anywhere the temperature drops below zero, the condition is more prevalent in some parts of the country than others. Find out about the weather and road hazard patterns in the area you will be traveling.

• Prepare any of your mechanics and subcontractors driving for the possibility of being stranded in bad weather. Remind everyone to carry winter clothing, including boots, gloves, and hats in their vehicles.

• If your mechanics don’t live in the snowbelt, winter driving hazards can be a big concern. You need to emphasize to them the special driving hazards and risks associated with longer hours of darkness and weather such as rainstorms.

Winter Hazards in the Workplace

But it’s not just the road that’s slippery in winter. Loading docks, stairways, equipment yards, parking lots, and other areas of the plant or facility can also become icy.

Adapt safety meetings to the particular fall hazards that are common to your work crew. Do they have to get in and out of vehicles in icy weather? Must they walk along loading ramps to do their jobs?

Steps, stairs, ramps, and ladders are all more dangerous in wet or icy weather, especially during the night shift. Remember that moist skin can stick to freezing surfaces. Check your work-site for areas that could be a particular hazard in the cold weather and discuss them in your morning toolbox meetings.

Effects of Darkness

The winter solstice around December 22 is the darkest time of the year. Outdoor workers are likely to be affected most by the increased darkness. But anyone who arrives or departs from work in the dark also needs reminding about special safety concerns, such as increased risk of slips, trips and falls, and personal security risks.

Be cautious using outdoor lighting around utility or construction jobs where flammable gas may accumulate.  It is importance to use light devices designed for decreased sparking.

The long dark winter can create or enhance symptoms of depression in employees, including lethargy, irritability, and forgetfulness. The depression can lead to increased use of alcohol and/or difficulty in relationships, which can further decrease employee productivity and awareness.

Early hours can also lead to dangerous fatigue; talk to the crew about getting enough sleep and coping safely with early shifts.

Make your safety talks address the particular risks cold weather creates on the specific tasks workers perform.

Cold Stress

Workers who are exposed to extreme cold or work in cold environments may be at risk of cold stress. Extreme cold weather is a dangerous situation that can bring on health emergencies in susceptible people, such as those without shelter, outdoor workers, and those who work in an area that is poorly insulated or without heat.

What constitutes cold stress and its effects can vary across different areas of the country. In regions relatively unaccustomed to winter weather, near freezing temperatures are considered factors for “cold stress.”

Prolonged exposure to cold, even at temperatures well above freezing, can result in abnormally low body temperature (hypothermia). A body temperature that is too low affects the brain, making the victim unable to think clearly or move well. This makes hypothermia particularly dangerous because a person may not know it is happening and will not be able to do anything about it.

Cold stress is accelerated if a body part is exposed to water. Water conducts heat away from the body faster than air. Local cooling can shut down circulation in the capillaries under the skin, which can result in permanent damage such as chilblains, trench foot or frostbite. These effects can be experienced at temperatures as high as 60 degrees F.

Whenever temperatures drop decidedly below normal and as wind speed increases, heat can more rapidly leave your body. Wear appropriate clothing and protect sensitive areas such as hands, feet and face.

Several layers of loose clothing will provide better insulation, especially if you alternate periods of exertion and rest. Wear a cap or rag under your hard hat. Stay in heated locations during work breaks, and limit outside exposure on extremely cold days.

Weather-related conditions may lead to serious health problems. So be prepared to cover up and stay warm.

The current heat wave engulfing the U.S presents big problems for all our employees.

Particularly at risk are those who work in high air temperatures and/or high humidity, near radiant heat sources, and/or engage in strenuous physical activities. In other words, conditions typically found on the turbine deck.

When a person works in a hot environment, the body must get rid of excess heat to maintain a stable internal temperature. We do this mainly through circulating blood to the skin and through sweating.

Cooling the body becomes more difficult when the air temperature is close to or warmer than normal body temperature. Blood circulated to the skin cannot lose its heat and sweating becomes the main way the body cools off. But sweating is ineffective in high humidity because the sweat can’t evaporate. In extremely low humidity, sweat may instantly evaporate from the skin, disguising the need to replace that vital water.

If the body cannot get rid of excess heat, the core temperature rises and the heart rate increases. Loss of salts (electrolytes) can impair muscle and brain function. Injury can also result from sweaty palms, fogged-up safety glasses, dizziness, loss of concentration, and burns from hot surfaces or steam.

Excessive heat can cause a range of illnesses, from heat rash and heat cramps to heat exhaustion and heat stroke. Initially, the person begins to lose concentration and has difficulty focusing on a task. He may become irritable or sick, and often loses the desire to drink. The next stage is most often dizziness or even fainting. Heat stroke can result in death and requires immediate medical attention.

The best way to prevent heat-related illness is to make the work environment cooler by staying in the shade and employing fans and adequate ventilation, or even air conditioning. If it is still hot, employ safe work practices such as enforced work/rest cycles, water breaks, and providing an opportunity for workers to build up a level of tolerance to working in the heat.

Be sure to include these prevention steps in worksite training and plans. Remember to refrain from alcohol intake the night prior and coffee during the shift. Alcohol, coffee and some prescription medications are diuretics which increase the rate of fluid loss. If the temperature is soaring and you are not urinating, you are not getting enough fluids.

It’s important to know and look out for the symptoms of heat-related illness in yourself and others.

Plan for an emergency and know what to do – acting quickly can save lives!