As we all know, the moment you enter an industrial facility, you’re instructed about who to notify in case of an emergency. And if something happens – no matter what the emergency – you can bet they’re going to call the rescue team. The question is, “When the call comes in, will your team be ready?”

Having taught rescue in industrial plants for more than 20+ years, I’ve observed how industrial rescue teams have been created and how they’ve been trained. I’ve also observed how they have responded to various types of incidents – including some rescue scenarios they could have never expected.

Over the years, I’ve also seen how the needs of rescue teams change. That’s one reason we continue to update and modify our training programs. We want the industrial teams that we train to be able to respond safely and effectively to all the various types of emergencies they may face at an industrial facility. Again, when help is needed, the onsite rescue team will be called!

Greater Demands on Industrial Responders

Back in the day, most sites typically only offered fire brigade training for their emergency responders. Eventually, medical was added, then hazmat, and finally confined space rescue – primarily in response to OSHA 1910.146. And, with permit-required confined spaces, most often comes the need for high angle rescue abilities as well. Once a victim is removed from a confined space, there is generally the need for raising or lowering the victim to ground level for medical transport.

As new regulations and standards have emerged, additional demands have been placed on industrial rescuers. This includes the new Confined Spaces in Construction Standard from OSHA (1926 Subpart AA). This new ruling provides construction workers with protections similar to those manufacturing and general industry workers have had for more than two decades. Differences tailored to the construction industry include requirements to ensure that multiple employers share vital safety information and to continuously monitor hazards – a safety option made possible by technological advances since 1910.146 was issued.

It is also becoming more difficult to justify "dialing 911" with the hope that the local fire department will be able to respond in a timely manner. Industrial sites are being forced to examine the reality of relying on local response agencies. And, in some cases, the plant’s industrial emergency response team may be the community’s best trained and equipped technical rescue capability. As one of our client’s stated after evaluating local response capabilities,

"We are truly an island unto ourselves. When it comes to certain types of emergencies, we're on our own!"

What Can Possibly Go Wrong?

We often focus on the importance of confined space and high angle rescue, but what about the other potential scenarios that industrial rescue teams may face. In recent years, we’ve seen an increase in requests from our clients in a wider variety of rescue disciplines – including Suspended Worker Rescue (Rescue from Fall Protection), Trench Rescue, Machinery Entrapment Rescue (“man in machine” is probably a better description), Water Rescue and Building Collapse for First Responders.

Let’s talk about these disciplines and how they can apply to industrial situations – keeping in mind that medical care will be required in most every situation. Many times those first on the scene have the greatest opportunity to make the difference for an injured worker. The first hour in a medical emergency is a crucial factor in increasing chances for survival.

Suspended Worker Rescue (Rescue from Fall Protection)

With expansion and construction work occurring in many facilities, you can often spot a variety of potential rescue scenarios just waiting to happen. For example, from stacks and vessels to scaffolding and towers, you will often find workers operating at varying heights

Here’s where the industrial rescue team must be ready for a timely response to Suspended Worker Rescue. Because suspension trauma can occur rapidly, time is of the essence. First of all, just reaching a suspended worker can be a challenge. Then, the victim must be raised or lowered to a safe area. Rescuers must have the appropriate equipment to keep themselves from harm’s way and be prepared to act quickly and efficiently.

Trench Rescue

Many sites will have some type of trenching job going on this year. Is your team trained to handle that type of collapse? Do you have the equipment for emergency shoring? Or, who can you call for help?

With an unsupported or improperly shored trench, it will collapse 100% of the time. It’s only a matter of when. Also keep in mind, even a relatively small cave-in involves about 1.5 cubic yards of dirt – or about 4,000 lbs. It is imperative that rescue personnel be trained and equipped prior to tackling one of these type emergencies – they are much more dangerous than they look!

Another key concern or consideration for trench or excavation work is “who” is signing off as to the safety of the trench? In talking with many of our clients, they may send an “entry supervisor” (company representative) to evaluate and sign off on a confined space permit. These individuals may have never been taught what to look for to determine if the protective system is adequate or installed properly. 

OSHA 1926.651(k)(1) states that a “Competent Person” shall inspect the shoring system. This refers to an individual 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.

OSHA Reference Excerpt [1926.651(k)(1)]
Daily inspections of excavations, the adjacent areas, and protective systems shall be made by a competent person for evidence of a situation that could result in possible cave-ins, indications of failure of protective systems, hazardous atmospheres, or other hazardous conditions. An inspection shall be conducted by the competent person prior to the start of work and as needed throughout the shift. Inspections shall also be made after every rainstorm or other hazard increasing occurrence.

Machinery Entrapment Rescue

As gruesome as it sounds, another eventuality in an industrial or manufacturing facility is someone getting caught in or under machinery or heavy equipment. Is your rescue team ready for this? In these instances, the rapid use of hydraulic spreaders or pneumatic lifting bags can mean the difference in life or death for an entrapped worker.

Consider the many applications that a simple lifting bag might have for rescue or maintenance work. For example, by sliding a one-inch thick lifting bag under or between two objects, you can lift up to 70 tons, up to 20 inches off the ground, depending on bag size. A bag like this could come in pretty handy at a plant or refinery. 

For these horrific incidents, you must consider how long it will take the municipal department to get to your site. Once on scene, are they familiar with the various types of equipment at your facility that may be involved? Do they understand the hazards of the working environment in an industrial facility?

Another gruesome part of machine rescue is impalement. This type of injury requires very specialized care. First of all, do not attempt to remove the impaled object! It needs to remain as is and transported with the patient to the emergency care facility. Again, the question is, who, what and where are the resources to handle this type of job?

Water Rescue

Does your facility have a dock? Do your people work over water? Do you have sediment ponds? If you answered yes to these questions, you should be asking yourself, “What will we do if someone falls in?” “Who will rescue them?” Or, are you going to depend on a coworker to jump in and try to save his buddy? Even basic “Throw, Don’t Go” training and some basic water safety equipment can make a huge difference in a person’s survivability. It could also prevent the situation from getting worse by failed heroic actions. Personal flotation devices are great, but what about when a worker gets swept under a dock or into a current? How will you handle these situations?

Building Collapse Rescue for First Responders

This one caught me off guard when requested by several industrial facilities, but it turns out there are some very good reasons for it. Considering weather disasters, explosions or acts of terrorism, it is a very real concern. Of course, this training for first responders isn’t the full program that is provided for FEMA or USAR teams, but it includes some very specific skill sets that can be extremely useful in industrial incidents.

Here are just a few examples. Emergency shoring techniques can be used to stabilize pipe racks or damaged structures for the rescue of injured workers. They also give industrial teams the ability to move heavy loads (5,000 to 10,000 lbs.) with simple hand tools. Remember, cranes can’t get everywhere, especially in a severely damaged area.

As emergency responders, we need to evaluate our capabilities continually and consider the types of rescue situations to which we may be called. We also need to know what outside resources are available – and, if it’s even possible for them to respond in a timely manner. Just like with confined spaces, we can’t simply dial 911 and hope they know what to do. While you hope it never happens, you’ve got to be prepared for the worst.

Many OSHA standards, especially in construction, require a “competent person” to be designated at the jobsite. Filling this role requires proper training, relevant experience to the work being performed and adequate knowledge of the associated regulations. 

The competent person should be able to recognize critical hazards as well as have the authority to take the action needed to mitigate hazards. It’s much more than just picking someone to fill a slot.

A previous article, "What is a Competent Person?" found in the National Safety Council's Safety+Health publication, talks about how the term is often taken too lightly. Again, it's much more than just selecting a body to fill a role or attending one 10-hour training class covering all the various standards. Competency must be considered and evaluated for this important role. 

At a minimum, your designated competent person should meet the following minimum qualifications:
(1)    A high level of understanding of the types of hazards typically encountered in that area of work;
(2)    A solid review of applicable standards relating to that type of work; and,
(3)    A thorough understanding of types of solutions to control or eliminate the hazards.

To assist in preparing your competent person in fall protection, we encourage you to register for Roco's Fall Protection Competent Person - April 4-5, 2016 course in Baton Rouge. This course will provide practical experience in recognizing fall hazards and developing appropriate measures for reducing or eliminating those hazards. 

Source: Safety+Health Magazine February 2016

Washington – A recent agreement between the Departments of Labor and Justice will launch a “new world of worker safety” by holding managers and supervisors criminally accountable for violations of the law, agency officials announced Dec. 17.

The two departments signed a memorandum of understanding that pools their resources toward the prosecution of individuals who willfully disregard labor and environmental statutes, according to John Cruden, assistant attorney general for the DOJ’s Environment and Natural Resources Division, who spoke at a press conference moments after the memo was signed.

For the past several years, OSHA and DOJ have worked with each other on certain cases, but the new agreement formalizes that relationship.

This cooperation could lead to hefty fines and prison terms for employers and individuals convicted of violating a number of related laws. For example, a roofing contractor recently pleaded guilty to violating an OSHA law, lying to inspectors and attempting to cover up his crime; he could be sentenced up to 25 years in prison.

“Strong criminal sanctions are a powerful tool to ensure employers comply with the law and protect the lives, limbs and lungs of our nation’s workers,” OSHA administrator David Michaels told reporters at the press conference.

Deborah Harris, DOJ’s Environmental Crimes Section chief, said prosecutions would be open to “the ones making the decisions that lead to the deaths of others,” which could include people in the corporate office, as well as managers and supervisors.

Readings are 20.9/0/0/0…so it must be safe for entry, right? Not necessarily!

After completing an interesting confined space standby job for Roco, I wanted to caution rescuers about the possibilities of atmospheric hazards within a confined space – despite what the atmospheric monitor says!

For this particular job, the atmosphere in the workspace never varied on the 4-gas monitor readings. The readings were consistently 20.9% for O2; 0 for LEL; 0 for H2S; and 0 for CO. However, this entry required the use of air-purifying respirators even though there were no visible signs of anything unusual – no odor, no product warning signs, no indication that there may be an inhalation hazard in the space.

This particular space was located at a public water facility. It was a 70-ft. deep concrete metering pit with six consecutive 12-ft x10-ft levels. It had concrete floors and walls with a vertical ladder that accessed each level. Although the space was not designed to store any product, in this case, we still had an atmospheric hazard.

The purpose of the entry was for remediation of mercury contamination on the concrete surface. The gross cleanup of liquid mercury had been performed years prior, but further action was required to eliminate vapor hazards still present in the lower chambers.

During the first phases of the entry, vapor levels that exceeded 40,000 ng/m3 (nano-grams per cubic meter) were detected. The more frequently updated ACGIH Threshold Limit Value is only 25,000 ng/m3. The work environment in this space routinely approached twice this level, even though there were no visible signs of liquid mercury. The source of the toxic atmospheric hazard was invisible and odorless – mercury vaporizing from the concrete surfaces.

Mercury is only one example of a toxicant that can produce a hazardous atmosphere in confined spaces that will not be indicated on a typical 4-gas meter or atmospheric monitor. Many rescuers assume that their 4-gas meter will detect all atmospheric conditions that may present a risk to their health or safety, but this is just not true. There are a wide variety of agents or toxicants besides mercury that will not be detected and whose presence may require other controls or the use of respiratory protection. This mistake could be deadly, or leave rescuers with chronic health issues.

In this scenario, for example, if you were an off-site rescuer responding to the above described space in an emergency situation. Without someone on site to inform you of the possible hazard, you would have no indication that any hazards were present. Many times as municipal rescuers we respond to, shall we say, shady locations where unauthorized storage or illegal dumping of hazardous products has taken place; there are no SDS, placards, or signage. Personnel on scene may not know, or may not want to relay vital information about a space of any products within the space.

Rescuers Beware: It's important to play the role of “detective” when planning or preparing to make a confined space entry.

Oftentimes, there are placards or signs on tanks or storage containers to start the investigation into what hazards may be present – and SDS for additional information. However, as rescuers, we often fall into a state of “false security” with our 4-gas meter readings.

While much of our training may include “Go/No Go” scenarios for rescue teams, the use of respiratory protection is usually based on one of the “Big 4” readings on our atmospheric monitors. Unfortunately, this may only serve to reinforce the notion that a 4-gas monitor will always provide the “complete” information of what may be going on inside a confined space. We get dependent on these monitors to tell us if it’s safe to enter without respiratory protection – and there may be much more to the story!

OSHA’s Respiratory Standard [1910.134 (d)(1)(III)] specifies "Where the employer cannot identify or reasonably estimate the employee exposure, the employer shall consider the atmosphere to be IDLH.” 

In the above statement, if you substitute Team Leader for “employer” and “Rescue Team” for employee, you may find that you cannot “identify or reasonably estimate the employee exposure.” Therefore, rescuers would need to use SCBA/SAR and other PPE until you can completely identify what hazards are in the space even though typical monitoring devices are telling us that all is well.

While your standard 4-gas meter is an important screening tool – it is NOT a "catch all" for every atmospheric hazard.

Remember that NIOSH statistics indicate that 40%-60% of confined space entry fatalities are (would-be) rescuers, including both dedicated on-site standby teams and off-site professional rescuers (municipalities) who attempt to perform confined space rescues.

But let’s take this a step further. If you ask most rescuers at what O2 level does an atmosphere become dangerous, they will say below 19.5%. I know from my initial hazmat/confined space training on 4-gas monitors included oxygen displacement. It was so elegantly described to me as “if your monitor shows a decrease in oxygen, it is telling you that something else has pushed out that percentage of oxygen and replaced it with some other agent.” Now, it would be up to you to figure out what else is in the air.

For example, normal breathing air is 20.9%. To get a reading of 19.5% means that about 1.4% of “something else” has displaced the oxygen. Then, depending on what that “something else” is, could require the use of respiratory protection. Hey, wait, the good news keeps coming, and I am getting in way over my head on this science stuff, but my high school chemistry teacher should still be proud. Ambient air is made up of about 79% nitrogen and other gases and 21% oxygen. So, using fingers and toes mathematics, that equals about a 4:1 ratio of nitrogen to oxygen.

In other words, if we have a 1% displacement of oxygen from the breathing air, it will be accompanied by about a 4% displacement of nitrogen (both gases displace at about the same rate). Therefore, instead of it being about a 1.4% percent of an unknown product in our breathing air, it could be as much as 5.6% or more! And, depending on what that product is, it could already be at its IDLH level.

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Project Scientist Spencer Pizzani of Weston Solutions provides this insight.

Depending on the manufacturer, you will find varying specifications for the service life of rescue equipment. For example, Petzl specifically defines the “potential” service life of plastic or textile products to be no longer than 10 years. It states "indefinite" for metallic products. CMC, on the other hand, does not give specified times for their equipment stating, “The service life of equipment used for rescue depends greatly on the type of use and the environment of use. Because these factors vary greatly, a precise service life of the equipment cannot be provided.” However, in reference to harnesses, CMC cites ASTM F1740-96 as the industry standard for service life. SMC follows along the lines of CMC when stating the amount of time a product can stay in service.

Although the definition of “equipment lifespan” is very broad depending on the manufacturer, each will provide specific instructions on proper inspection of equipment and detailed explanations on when to retire the item.

Most manufacturers follow the same general guidelines for removing equipment from service. Several general identifiers that pertain to all equipment are shown below.

REASONS FOR EQUIPMENT RETIREMENT INCLUDE:

• Item fails to pass any pre/post use or competent person inspection.
• Item has been subjected to a major fall or load.
• Item is constructed of plastic or textile material and is older than 10 years.
• You cannot determine the complete full-use history of item.
• You are not certain or have lost confidence in the equipment.

Most manufacturers will provide service for equipment items that are repairable. However, most caution against this because the cost of repair typically exceeds the cost of replacement. Any repairs attempted outside of the manufacturer may void any warranty and will release the manufacturer from any liability or responsibility. In addition, all manufacturers recommend destroying equipment once it has been retired from service to prevent items from inadvertently being recycled back into active service gear.

Regardless of the stated service life, the condition of equipment–as determined through inspection by a qualified party – is a key factor in determining whether or not a piece of equipment is fit for service.

Manufacturers also provide indicators for different types of equipment that require it to be retired from service. These are not only capturing the general conditions mentioned above, but also bring in conditions that are specific to each category of equipment. It is important to identify these specific conditions as they are vital to the dependability and functionality of each component.

Harnesses:

Harnesses are one of the most vital components of life safety equipment. Without a certified harness in serviceable condition, the best life safety rope and hardware in pristine condition will do little to protect the user. All individuals who are required to wear harnesses to perform duties should be trained and authorized in the inspection process. Harnesses should be inspected before and after use as well as once annually by an individual deemed a competent person by the facility or department.

Since harnesses are a nylon product, they fall under the guidelines set forth by ASTM consensus standard F1740-96 and have a service life of 10 years. Manufacturers also state that hard or excessive use – as well as the conditions when a harness is used – may significantly reduce its service life. It is important to conduct routine inspections as well as keep records of harness use. This “usage” history could indicate signs that would require the equipment to be retired early.

Here are some conditions to help identify when it’s time to retire your life safety harness:

• The harness has surpassed 10 years since the manufacture date.
• Webbing shows signs of cuts, significantly worn or frayed areas, soft or hard spots.
• Webbing shows signs of discolored or melted fibers.
• Stitching shows signs of pulled threads, abrasion or breaks.
• Hardware shows signs of damage, sharp edges, excessive wear or improper function.
• If the harness has been subjected to shock loads, fall loads, or abuse.
• If there is any doubt about the integrity of the harness.
• If the harness demonstrates any of these conditions, it should be removed from service and destroyed.

Life Safety Rope, Webbing, Anchor Straps, Accessory Cord:

Since these products are nylon or textile based as well, they fall under the same inspection process as harnesses. A complete inspection of life safety rope and associated products includes not only a visual inspection but a tactile (or touch) inspection as well. The tactile inspection should be done with tension on the rope, webbing or strap.

The inspector is looking to identify any of the following conditions:

• Chafed, glazed or discolored surfaces (these areas should receive a more thorough inspection).
• Abrasions or cuts in the sheath where the core is exposed.
• Variation of diameter of the rope that could indicate potential damage to the core fibers.
• Soft or hard spots that could indicate core damage or that the fibers have been over stressed.
• If the rope has been subjected to shock loads, fall loads or abuse.

If any of these conditions are noted, then the item should be retired and destroyed immediately. It is important to remember that an accurate history should be maintained for all life safety rope products. The date of manufacture should be identified and recorded as products are being put into service. Equipment inspectors or users should ensure that these products do not exceed their service life. As with harnesses, the amount, type and conditions of use can drastically reduce the service life of these products.

Carabiners:

Since carabiners are metallic, they do not fall under the ASTM service life recommendation of 10 years. As long as these products are in serviceable condition and properly maintained, they have an infinite service life. Even though they do not have a dedicated service life term, it is still important to conduct the same pre/post use and annual inspections.

Some conditions that would require the equipment, such as carabiners, to be retired from service include:

• Carabiner has been dropped a significant distance.
• Exposed to heat sufficient enough to alter the surface appearance.
• Cracks, distortion or deep gouges.
• Corrosion or deep pitted rust. (Note: Surface rust may be removed with a fine abrasive cloth and coated with a preservative such as LPS #1.)
• Sharp edges that could cause damage to life safety rope (minor edges may be smoothed with the same process as rust removal).
• Gate does not line up when closed.
• Gate action does not return to closed position when opened and released.
• Locking mechanism does not fully engage.
• Complete history of use cannot be determined.

If any of these conditions exist, the equipment should be removed from service and destroyed. Records of use and inspection should be kept on these items even though the service life of the product is infinite.

Pulleys:

Pulleys, as with carabiners, are metallic in construction and do not have a service life recommendation. They will also have an infinite service life as long as they are in serviceable condition and are properly maintained. Pulleys fall under the same inspection requirements as carabiners. 

Below are some conditions that would require such equipment to be removed from service:

• Pulley has been dropped a significant distance.
• Exposed to heat sufficient enough to alter the surface appearance.
• Cracks, dents or elongation at the carabiner hole on side plates.
• Corrosion or deep pitted rust. (Note: Surface rust may be removed with a fine abrasive cloth and coated with a preservative such as LPS #1.)
• Deep scratches or gouges to side plates or sheave(s).
• Sharp edges that could cause damage to life safety rope (minor edges may be smoothed with the same process as rust removal).
• Side plates that do not line up at the carabiner hole.
• Elongation of the side plates at the sheave pin.
• Side plates that do not move freely.
• Sheave does not turn freely or significantly rubs against side plate.
• If the item has been subjected to shock loads, fall loads or abuse.
• If the history of use or manufacture date cannot be determined.

If any of these conditions exist, the equipment should be removed from service and destroyed. Records of use and inspection should be kept on these items even though the service life of the product is infinite.

Descent control devices:

Descent control devices, if metallic, do not have a service life recommendation. If the device is constructed of plastic or other textile material, it will have a service life not to exceed 10 years.

conditions that would require this equipment to be removed from service:

• Cracks, deformations or elongation to any portion of the device.
• Corrosion or deep pitted rust. (Note: Surface rust may be removed with a fine abrasive cloth and coated with a preservative such as LPS #1.)
• Deep scratches or gouges to any portion of the device.
• Sharp edges that could cause damage to life safety rope (minor edges may be smoothed with the same process as rust removal).
• Excessive wear to friction surfaces or cam (see wear indicator on some devices).
• If the device has been subjected to shock loads, fall loads or abuse.
• If the history of use or manufacture date cannot be determined.

If any of these conditions exist, the equipment should be removed from service and destroyed. Records of use and inspection should be kept on these items throughout their service life.

Ascenders:

As with previously mentioned equipment, the same inspection procedures apply to ascenders. 

 remove from service if you find:

• Cracks, deformations or elongation to any portion of the device.
• Corrosion or deep pitted rust. (Note: Surface rust may be removed with a fine abrasive cloth and coated with a preservative such as LPS #1.)
• Deep scratches or gouges to any portion of the device.
• Sharp edges that could cause damage to life safety rope (minor edges may be smoothed with the same process as rust removal).
• Fouled teeth on cam (handled type ascenders).
• Excessive wear to surface of cam.
• Damage to rivets (if applicable).

If any of these conditions exist, the equipment should be removed from service and destroyed. Records of use and inspection should be kept on these items throughout their service life.

Service history is an extremely important part of ensuring life safety equipment is properly maintained and that service life is not exceeded. Not only does this help rescue teams control inventory and operational capability of equipment by documenting each use and inspection, it also assists the teams in forecasting budget costs for the replacement of items that are nearing the end of their service life.

Maintaining records of the manufacturer’s information received when purchasing new equipment is vital to identifying and keeping track of the manufacture date. It is also important to keep this information on file for the exact procedures for inspecting and removing equipment from service. If the manufacture date of equipment, such as life safety rope and harnesses, cannot be identified; it poses extreme liability for agencies or facilities whose teams may potentially be operating with equipment that has passed its service life. It could also create a compromise in the safe operation of the equipment. Also, if record-keeping of equipment inspection and use is not a primary focus, it could potentially expose team members to operating with unsafe equipment due to abuse or excessive/extreme conditions that go undetected.

All team members should be qualified and knowledgeable enough to perform pre- and post-use inspections of equipment. It is crucial that all members document each use of equipment, denote any deficiencies, and report to the proper person. One person should be designated to perform the competent person annual inspection. This person should have complete knowledge of the equipment and inspection procedures as well as the authority to keep or remove equipment from service as they see fit. If team members are unable to fill this role, a qualified third party with applicable manufacturer certifications in competent person inspection should be brought in to assist in determining the condition and estimated service life of rescue equipment. For assistance from our rescue equipment professionals, call us at 800-647-7626.

Additional Resources

Gear Inspection Checklist (download)

Cleaning Your Rope…Here’s What the Experts Have to Say

Guidelines for Permanent Marking of Rescue Hardware