Sunday 14 November 2010

Allen-Bradley PLC 5/40


PLC 5/40 Details
  • The front face showing Status LEDs, Communication Ports, Keyswitch, Battery and EEPROM installation
  • The LEDs are for (from the top) Battery status, Processor status, Force status and Channel 0 communication status
  • Apart from that, Each port (1A,2A,1B,2B) having their own status LEDs
  • The steady green shows healthy, Red for fault
  • 1A  and 2A Channels are used for Serial data transfer to DCS on DH+ Network
  • 2B used for Panelview/MMI on PC/Redundant I/Os
  • 1B used for RIO communication
  • Channel 0 is for RS 232/ RS 422 Communication with the PC
  • Lithium battery is for retaining the program in Processor when it is Powered OFF.
  • EEPROM is to provide memory backup when processor memory corrupted

PLC In Refinery
  • Mainly Allen-Bradley make
  • PLC 5 and SLC family
  • PLC 5/40 Having CPU Level Redundancy
  • PLC 5/40L, 5/60 And SLC Installation
  • Controls Operation of the Compressors, Heaters, Filters, F&G, Analyzer Safe Guarding and Other package units

Processor Architecture






PLC System Architecture
  • Input means Signals from Proximity switch, pressure switch, pressure transmitters etc.
  • Output means I/P converter, relay etc.
  • This Inputs and Outputs are connected to the Digital Input cards, The digital output cards, Digital Output cards, Analog Input cards, Analog Output cards installed in the Remote I/O Chassis
  • The PLC having local Chassis and Remote I/O Chassis
  • The Remote I/O chassis is connected with PLC thru Belden 9463 (blue Color)
  • Why Remote Chassis are required?
  • Remote I/O adaptor Card is required for the Communication with the Processor. It always  remains in the first slot of the Chassis
  • The Power Supply card in the Chassis is required to supply power to the complete chassis
  • The 110Vac power supply is required for Power Supply card
  • There are two Local chassis containing Processor.
  • One processor is in primary mode and the other is in secondary mode
  • The processor is having node address which can set by switch settings on the card
  • The primary processor is connected on the DH+ network
  • The connection is made in the Station connector normally mounted near to the chassis
  • The primary processor appears as node no “n” in the DH+ network and the secondary processor appears as “n+1” in the network
  • The KF2 module is connected on the network
  • KF2 Module Converts DH+ data into RS-232 Signals which is compatible with AB Integrator in DCS architecture
  • The KF2 and AB Module are act as link between PLC and DCS  
  • The Panel view is used for monitoring the data of the  process as well as controlling the operation
  • It is connected to the 2B channel of the processor
  • The baud rate used for communication is 57.6 K
  • Programming Terminal for Viewing, Modifying and Configuring the PLC Programming

Signal Flow In PLC
  • The Field Signals are connected with I/O cards in RIO chassis
  • Processor taking data from RIO chassis thru Remote I/O link and stores in I/P image tables / memory
  • The data is being updated on every scan of the PLC
  • The data is processed in Processor according to the program written
  • The result is transferred to the output cards in RIO Chassis.
  • The Output will be in the terms of 4-20mA or Contacts.
  • The Processor updates the data on every scan, The scan time is in terms of milliseconds (averagely 40 mS)
  • The scan of the processor means processor doing input scan, then program scan, then output scan, service communication and housekeeping. The time taken for completing this activities once is call scan time
System Redundancy
  • Redundant DH+ Network for communication with the DCS (A and B network for DCS)
  • The BEM cards are installed for increasing the no. of communication channels available for networking.
  • Redundant 1770-KF2 modules for communications with DCS
  • Both the PLC executes Application program
  • Primary processor controls the I/O, but Secondary can monitor only
  • The Switch over between processor is doing by BCM and BEM card

Software
  • The program can written in Ladder Logic, Sequence function charts or Structured text format
  • We have used Ladder Logic
  • The Programming package is RsLogix5 (Windows based) and 6200 series Software (DOS based)
  • The Software package can load into PC / Laptop
  • The PC requires KT card and the Laptop requires PCMK card
  • If KT/PCMK not available, then Processor can communicate on COM port of PC/laptop Serially thru CH0 on processor
  • The RsLinx software is also required for the Communication over the network and serially
  • The PLC program is protected with 4 different level access passwords
  • In our complex, there is no password for the Reading the program online
Diagnostics
  • There are status LEDs on the processor face
  • The first LED is battery status indicator, if it glows RED, then Either the battery is low or missing
  •  If the Second LED is steady green, processor is healthy
  • If it is flashing red, the program downloading is under progress or major fault, for steady red, hardware fault
  • The force glows steady amber when any I/P or O/P are forced in the program
  • If Comm LED flashing green, the Channel 0 communication is working
  • Any of the channel status LED glowing steady green, then that channel is healthy
  • If it glows flashing Green, bad communication
  • When it is red, adaptor fault                           

Tuesday 9 November 2010

Hand Protection - Handle with Care

Next to our eyes, our hands are probably the most important part of our body when it comes to doing our work. They’re involved in almost every thing we do. Yet many of the things we do with our hands are done without any deliberate thought. Your hands have no fear. They’ll go anyplace they’re sent and they only act as wisely as the person they belong to; so before you use your hands think of their safekeeping.
Here are the most common types of hand injuries and what you can do to prevent them:
Traumatic injuries often occur from careless use of machinery or tools. Hands and fingers get caught, pinched or crushed in chains, wheels, rollers, or gears. They are punctured, torn or cut by spiked or jagged tools and edges that shear or chop. Safety precautions should include using shields, guards, gloves, or safety locks; handling knives or tools with care; and keeping hands, jewelry and clothing away from moving parts.
Contact injuries result from contact with solvents, acids, cleaning solutions, flammable liquids and other substances that can cause burns or injure tissue. To protect against these injuries, read the product labels, use the right glove or barrier cream, and wash hands frequently. result from contact with solvents, acids, cleaning solutions, flammable liquids and other substances that can cause burns or injure tissue. To protect against these injuries, read the product labels, use the right glove or barrier cream, and wash hands frequently.
Repetitive motion injuries happen when tasks require repeated, rapid hand movements for long periods of time. Manufacturing, assembling, or computer work may lead to these injuries. Change your grip, hand position, or motion. If possible, rotate tasks to give your hands a rest.
You can protect yourself from hand injuries by remembering the following basic safety rules:
  • Recognize hazards.
  • Think through each job before you begin.
  • Follow safety rules.
  • Avoid shortcuts.
  • If an accident happens, seek prompt treatment.
  • Report injuries to your supervisor.
Healthy hands are built to last a lifetime. Injuries can last a lifetime, too. Be aware of your hand placement and take precautions to guard them.

Fire Safety - In Case Of Fire

You are responsible for fire prevention at work for your safety and that of your co-workers. The best way to prevent workplace fires is to be aware of and on the lookout for potential fire hazards. Report hazardous situations to the supervisor. Know the location of fire extinguishers and other emergency equipment that is available to you. During an actual emergency, protect yourself. Do not get involved if it is not safe.
If you ever discover a fire, keep your cool but think fast and act with caution. Size it up fast; knowing when to attempt extinguishing the fire yourself and when to call for help is essential.
In case of fire, follow your company’s fire response procedures. The important thing is to know what to do and do it fast. The exact order to do the things depends on the established company procedures.
Sound the alarm and evacuate the area. Call the emergency numbers you’ve been given, and give the details about the fire (location, how it started etc.). Never hesitate to call the fire department, even if the fire seems minor and you manage to put it out before firefighters arrive. The quicker the alarm is sounded, the sooner firefighters can attempt to get it under control. Have someone meet the firefighters to tell where the fire is. They can lose valuable minutes if they have to find it themselves.
You are responsible for preventing fires, but not to put out major fires. Fight the fire only if you can do it safely with proper extinguishing materials. In general, never battle the blaze unless the firefighters request your help.
Warn anyone in the area so they can get to safety. This is especially important with indoor fires. Most people die from smoke, poisonous gases and panic (usually the result of not knowing what to do). If there is an escape plan, adapt it to the emergency.
Most fires start small, but they can rage out of control in a few minutes. It is important to know where the fire extinguishers are located and how to operate them properly. Distinguish before you extinguish. Choose the correct extinguisher for the type of fire (paper/wood, grease/gas/flammable liquids, electrical). If you are not trained or authorized to use an extinguisher, don’t try. The time you waste in figuring out how to operate an extinguisher could mean the difference between minor damage and a major disaster.
Review your company’s fire safety procedures often so you’ll now what to do. Act with caution. Sound the alarm. Warn others in the area. Evacuate and stay back unless you’re asked to help. In case of fire, being informed and prepared can keep you and your co-workers safe from injury.

Detention Facility Worker

Personnel in detention and prison facilities should be continuously aware and constantly prepared for the risks they face on the job. Work in these facilities can be extremely stressful both physically and mentally for guards, custodians, or medical personnel. Workers also run the risk of exposure to physical attack or infection from bodily fluids.
Security personnel perform facility inspections to ensure inmate safety and custody. When walking the grounds and perimeter, watch for uneven ground that can cause trips and falls. When you inspect roof vantage points, stay at least 6 feet from the edge if it does not have a guard rail.
Everyone should inspect the workplace for hazards and correct or report them. Maintain good housekeeping. No items should be stored or even temporarily piled in walkways or exits. Ensure that lights, locks, and flooring are in good repair. Equipment such as carts and communication devices must be in working order. Evaluate chemical storage and use at your facility; prevent inmate access to concentrated chemicals that could be used as a weapon. Maintain strict control of knives and other sharps that could be used as weapons.
You know how dangerous violence in your workplace can be. Inmates may fight each other or attack workers. Stay in top physical condition and remain alert when you work in the facility. Get training such as managing aggressive behavior and verbal judo to help control behavioral crises. Have an emergency code and response plan for these incidents. Practice and drill the response frequently and in different scenarios.
Bloodborne pathogen exposure from splashes or contact with blood is a serious hazard when violence erupts. The most common exposure is a splash of blood or other bodily fluids to a mucous membrane (eye, nose, mouth) or a puncture from a bite, scratch, or other wound. If you are required to respond to these emergency incidents, wear body armor, long sleeves, and pants to protect your body. Gloves and safety glasses or goggles protect you from accidental splashes. Evaluate different equipment to ensure that it does not hamper your response while protecting you.
Avoid situations where an inmate can use blood, urine, or feces as a potential weapon by controlling access to cups and containers and wearing the appropriate protective gear. Use proper techniques to enter inmate cells. Know what to do if you have an exposure, including who to report it to and how to follow-up with medical attention. Vaccination for Hepatitis B, one of the most easily transmittable blood borne diseases, protects your health.
Tuberculosis (TB), a respiratory disease, is a concern in detention facilities. If you suspect an inmate has TB, isolate and transport them for medical attention. Use respiratory protection such as an N95 respirator when entering isolation rooms or working with potentially infectious inmates. TB vaccination is not common in the United States, so get a yearly TB test to ensure you have not been exposed.
Your work environment can be indoors, outdoors, and physically challenging. Wear comfortable layers of clothing and sturdy, comfortable footwear. Get plenty of rest and eat healthfully to maintain your awareness on the job and help your body cope with demanding shift work. Maintain your fitness so that you can respond to any type of emergency on the job.
The level of required alertness and the unpredictable nature of the inmates in your workplace cause stress. Good fitness and overall health help you better manage job stress. Get the training you need to feel prepared and in control at work. Talk about your job tasks and stresses with your supervisor to get guidance on controlling stress. After emergency incidents, get debriefing counseling individually or as a group to help you cope with the emotions and stress.

Common Sense Safety


There are a number of safety problems common to most workplaces and job sites that can be solved with a little common sense. Planning and thinking ahead can help eliminate most of these hazards. Take a close look at your workplace with these suggestions in mind.
Eliminate junk piles. Organize a cleanup program to remove trash, broken parts, and scrap from work areas, walkways, storerooms, and neglected corners. Look for materials that have been stacked improperly. An unstable stack is a real danger to anyone who may be near if the material suddenly falls. Check such things as wood pallets, dock freight, storeroom boxes, construction materials and even office files to see that materials are stacked properly.
Examine all the operations of your workplace to determine if personal protective clothing is needed, then make it readily available. Ear protection, eye protection, hard hats, gloves, safety shoes or other protective clothing and equipment must be worn according to the hazard exposure.
Make sure all electric power tools are grounded. Protect yourself from electric shock by using tools with three-prong plugs, a ground-fault system or double insulation. Never cut off the ground plug on a three-prong plug. Check electrical cords and wires for any damage. Guard power tools and moving machine parts. Tools and equipment should never be operated with the guards or shields removed.
Inspect portable ladders to make sure they are secure and don’t shake or wiggle. Nonslip feet are a must. If a ladder seems weak, get rid of it – don’t let others use a defective ladder. Mark it defective and throw it away.
Fire extinguishers are a must and should be mounted properly, readily accessible, and in working order. Check fire regulations to make sure they are properly placed and the right type for your work area. When was the last time your fire extinguishers were tested? Extinguisher inspections should be made regularly then tagged to show when and who performed the tests.
Exits should be clearly marked with easy to read signs place above the doors. Signs with arrows should also be used to guide people to the exit if the layout of the workplace is confusing to those unfamiliar with your facility. Illuminated signs should be kept in working order at all times. Don’t block exits or signs with vehicles or material. Another good idea is to mark doors that are not exits with “This is Not An Exit,” “Restroom,” “Storeroom” or “Closet.” Put rails on all stairways. The stairs themselves should be in good shape with nonskid treads. Repair those that are damaged or chipped.
Safety meetings are one of the most important parts of a good safety program, so hold them regularly. Impress upon every worker that it’s important that they take every precaution to keep the workplace safe. Both employee and employer attitudes toward safety provide a key to a successful safety program. Posters, handouts, and training programs can all be part of your safety communication.

Back Injury Prevention

Back injuries are cited as the most common reason for absenteeism in the general workforce after the common cold. About 80 percent of adults are estimated to experience a back injury in their lifetime, and about 10 percent will suffer a re-injury.
Organizations are taking steps to reduce back injury in the health-care workplace, most prominently the U.S. Occupational Health and Safety Administration (OSHA). For example, OSHA released final ergonomic guidelines for nursing homes, offering guidance to workers when it comes to lifting home residents or other large objects. Additionally, OSHA entered into its first strategic alliance with a medical association - the American Academy of Orthopaedic Surgeons (AAOS). Both organizations plan to use their collective expertise to reduce and prevent ergonomic injuries in the workplace
National health-care statistics: In the United States, back disorders account for over 24 percent of all occupational injuries and illnesses involving days away from work, according to the National Institute of Occupational Safety and Health's (NIOSH) Worker Health Chartbook, 2004. In healthcare, back injuries, frequently caused by overexertion, occur at a very high rate. Healthcare industry workers sustain 4.5 times more overexertion injuries than any other type of worker. (See the U.S. Department of Labor, Bureau of Labor Statistics, 2000.) According to national statistics, six of the top 10 professions at greatest risk for back injury are: nurse's aides, licensed practical nurses, registered nurses, health aides, radiology technicians, and physical therapists. Greater than one third of back injuries among nurses are attributed to handling patients and the frequency with which they are required to manually move patients. From a worldwide perspective, back injuries to nurses have point prevalence of approximately 17 percent, an annual prevalence of 40-50 percent and a lifetime prevalence of 35-80 percent. (See A Business Case for Patient Care Ergonomic Interventions, 2005). As staggering as these statistics are, they still do not tell the whole story. According to Bernice Owen, RN, Ph.D., former professor at the University of Wisconsin-Madison School of Nursing, as many as one-third of nurses who sustain work-related back injuries do not even report them. (See Caring for Ourselves, by Bernice Owen.)
Personal impact: About 80 percent of back injuries are short in duration, and workers are able get back to normal health. In the short-term, they may experience pain and reduced functioning. For some, the pain and suffering is long-term. And for a small percentage of people, it is lifelong. For employees with long-term, disabling musculoskeletal injuries, lifetime earnings may drop significantly. These employees may also suffer a loss of independence and a diminished quality of life.
National impact: With a critical nursing shortage, back injuries among nursing personnel can seriously diminish the nation's ability to provide quality care. The following recent resources describe the crisis:
  • Nursing workforce, General Accounting Office report,
  • Hospital nurse staffing and patient mortality and
  • A white paper from the Joint Commission on Accreditation of Healthcare Organizations.
Organizational causes: Many factors affect back injuries among healthcare personnel: an aging workforce, sicker patients, staffing shortages, obesity in both patients and employees, gender, and stress due to organizational change.
Individual causes: Back pain and other work-related musculoskeletal injuries may be caused by:
  • A single traumatic event, such as a slip and fall or a car accident.
  • Other factors, such as genetics; age (older populations experience an increase in arthritis and disc degeneration); being out of shape or overweight; having poor posture; bending, standing, sitting, or lifting improperly; tension, emotional problems or personal stress; pregnancy; tobacco smoking; poor physical condition; and sports or hobbies.
  • Cumulative trauma to the spine and related structures.
Equipment solutions: Preventing serious back injuries must include the use of patient lifting and transfer equipment for most patients, but especially for obese (bariatric) patients. A Patient Lift and Transfer Resources List may be helpful in identifying companies, examples of equipment (including bariatric patient needs), and contact information. In addition, an organizational assessment will reveal the various types and numbers of equipment needed, which depends on the patient population and the type of care provided. A proposed Injury Prevention Program is described below in this module.
Special concerns - the bariatric patient: Lifting and transferring of bariatric patients has become a concern for many organizations and healthcare personnel. It is estimated that about five to 10 percent of the general population is obese. Due to their weight and size, special considerations can reduce the potential lifting hazard for caregivers. To determine obesity, one may refer to the chart conversion.
When the BMI is greater than 38, there is a possible need for special bariatric equipment. If the BMI is greater than 39, the patient is considered morbidly obese.  For example: a 5'8" tall, 255-pound person has a BMI of 39.
Special considerations are not only needed to meet quality of care standards for these high-risk patients, but to also prevent potential lift and transfer injuries to caregivers. Often, the lifting assistance available on site is not rated for use with bariatric patients.
A process for identifying equipment needs and a list of types of equipment to consider may be found in "Bariatric Equipment Considerations," included in the sample procedures and tools section of this module.
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Identify potential solutions: Based on the data gathered, solutions to correct the problem may be formed. The plan should:
  • Define the criteria to determine when assistance is needed.
  • Determine the need for lifting equipment.
  • Review affected policies and procedures to incorporate changes.
  • Review training needs for both supervisory and patient care personnel.
Criteria: The final program combines work practices, equipment use, and body mechanics. How each is incorporated depends on the goals set by the organization. In OSHA's guideline, the goal is to "minimize manual lifting of [patients] in all cases and eliminate it when possible," (See Ergonomics for the Prevention of Musculoskeletal Disorders: Guidelines for Nursing Homes).
Determine need for lifting equipment: Organizations must first determine the need for patient transfer equipment, both for the majority of patients and for the obese. This will vary depending on the type of care provided and the patient population served. Algorithms describing what assistance to provide in various lifting situations may be helpful. Then, organizations must decide what types of equipment are needed. An equipment criteria worksheet and the previously mentioned patient lift and transfer resources may provide some direction at this stage. Finally, organizations must be clear on how frequently the equipment will be used.
Policies and procedures: Policies and protocols should be unique to each organization. In developing policies, organizations need to ensure consistency with their injury reporting process and return-to-work programs as related to back injuries. When lifting assistance is considered a critical part of the program, caregivers need clear direction on making decisions on assistance. Only then can they be held accountable for following the lifting requirements. A sample policy from the Veteran's Administration may suggest further ideas for consideration.
Training: Training needs should be identified and provided for all levels of personnel. This includes:
  • Caregiver management, so they will support the use of safe lifting practices and equipment.
  • Caregivers, so they understand the benefits and are comfortable using the equipment.
  • Maintenance personnel, so they can complete preventative maintenance tasks.
Gain top management support: Perhaps the biggest initial hurdle program promoters face is getting management approval for implementing a program that, by its complex nature, necessitates a great deal of organizational commitment and resources to be successful.
Strategies to gain support: How do program promoters get upper management buy-in to program change? Most organizations have basic back injury prevention programs. However, most are either incomplete or not comprehensive as evidenced by statistics indicating injuries from lifting and transferring patients continue to occur and in fact, are increasing. Senior management may not see the need to add additional resources to support a more complete program.
Suggestions to enlist leadership support for program change include:
  • Change the focus: Many decision-makers grapple with the fact that money has been spent on back injury prevention programs before, yet back injuries continue to occur. Management may be even more reluctant to invest in another potentially unsuccessful program. To help overcome this hurdle, one group decided to change the focus of the program. Rather than preventing back injuries in patient care personnel, they promoted improving patient care. Even the program title was changed to reflect this approach: "Preventing Back Injuries in Nursing Care" became "Patient Handling and Movement." Regardless of the term chosen, if the focus includes patient care, decision-makers may be more receptive to providing the extensive backing - and monies - required by a truly successful program.
  • Review the current legislative environment: The Occupational Safety and Health Administration (OSHA) has listed ergonomics, especially in health care, as a top priority. (See news release "OSHA Announces Comprehensive Plan to Reduce Ergonomic Injuries, April 5, 2002.) Additionally, OSHA's citable general duty clause states that a workplace should be "free from recognized hazards." Overexertion injuries from lifting people have been formally recognized as workplace hazards, ever since OSHA ruled that overexertion injuries resulted from lifting and transferring of residents. (See news release Nursing Home Company Settles Case-Beverly Adopts Ergonomic Measures to Reduce Back Injuries, January 15, 2002).

    JCAHO surveyors have also taken a greater interest in employee and patient safety issues related to lifting and transferring. For example, organizations report that surveyors have asked to see their OSHA 300 logs. The surveyors then asked about preventative measures taken for the most frequent and/or costly types of injury, many of which are musculoskeletal disorders.
  • Demonstrate success: Data are critical to demonstrating proven injury-prevention systems. Facilities implementing ergonomics-based injury prevention programs with effective engineering and work practice controls have achieved considerable success in reducing worker-related injuries and workers' compensation costs. Some institutions have experienced additional benefits, including reduced staff turnover and associated training and administrative costs, reduced absenteeism, increased productivity improved morale, reduced resident injury and increased resident comfort. Many examples exist of effective ergonomics program in nursing homes. The following examples highlight some aspects of successful programs:
     
    • Citizens Memorial Health Care Facility in Bolivar, Missouri: In the four-year period following implementation of a program that combined the use of assistive devices and staff education OSHA-recordable lifting-related injuries were reduced by 45 percent annually with a direct savings of $150,000 in worker's compensation costs.
    • Kennebec Health system, August, Maine: Following the implementation of an ergonomic management program that included the use of lifting devices, the system reduced lost workdays from 1,097 to 48, and lowered its insurance premium from $1.6 million to $770,293.
    • Surrey Memorial Hospital, British Columbia: After implementing an ergonomics-based program with a "no lift policy," the hospital reduced injuries by 95 percent.
    • Veterans Health Administration (VHA), Florida: A financial evaluation conducted two years after the implementation of a project aimed at reducing the number of injuries to nurses and nursing associates with direct patient handling, showed an annualized savings of greater than $200,000 per year including medical care and associated employee costs. An 18 per cent decrease in missed work days due to work-related injuries was also demonstrated
Direct costs include workers' compensation, medical treatment, and vocational rehabilitation. Estimates of the total cost of low back pain to society in 1990 were between $50 billion and $100 billion per year, with a significant share (about $11 billion) borne by the workers' compensation system. (National Occupational Research Agenda (NORA) Priority Research Areas: Low Back Disorders. April, 1996) The observed average costs per healthcare staff-related musculoskeletal injuries per 100,000 work hours are greater than $160,000. (A Business Case for Patient Care Ergonomic Interventions, 2005) Nationally, the estimated average cost per claim is $24,000. If surgery is involved, the cost for claims increases significantly to $40,000 per injury or higher. One example of a back injury involving surgery totaled $240,000.
The Wyandotte County Nursing Home in Upper Sandusky, Ohio, reported that staff had suffered back injuries, including a single injury that resulted in worker's compensation costs of $240,000. The facility acquired 18 ceiling lifts, as well as portable total lifts, a sit-to-stand lift, a lift walker, and 58 electrically adjustable beds at a cost of approximately $150,000. Since Wyandotte implemented a policy of performing all assisted resident transfers with mechanical lifts or gait belts, back injuries from resident lifting have been eliminated. Increased efficiency has allowed staff members to spend more time with residents and caregiver's attitudes and energy levels have reportedly improved. In addition, residents no longer complain of shoulder pain and bruises that had previously been associated with manual resident handling. (Source: OSHA draft guideline)
Indirect costs: Indirect costs, while much harder to quantify, have a significant impact on quality patient care. Many experts estimate that indirect costs are four to seven times higher than direct costs and may cause: decreased employee morale, continual employee hiring and training, use of replacement workers, overtime, medical management, incident reporting and other paperwork, the increased costs of workers' compensation insurance, and the increased costs of employee healthcare.
Many of the organizational costs of back and other musculoskeletal injuries can be quantified through use of a cost benefit analysis adapted from the VA guide.
The cost to the patient: Inadequate solutions for patient lifting and transferring also result in costs to the patient, both physical and psychological. For example, the manual lifting of patients can result in skin tears from being dragged across surfaces. Skin injury can also be caused from using pants instead of a gait belt for a handhold.
Another frequently used but dangerous manual lifting technique involves lifting a patient under the arm, in the sensitive axilla area, and then transferring them. Using this technique, often called "hook and toss," patients are "hooked" under the arm and "tossed" to a new location. This transfer, used because of simplicity and speed of execution, is often painful for the patient. It may also result in subluxation (shoulder joint separation) or other shoulder and upper arm injuries.
There may be psychological distress to the patient as well. For example, when manual techniques are used for lifting, larger people often feel badly that a caregiver will have to lift their weight. As a result, some may not let their caregiver know that they have to use the restroom. Chronic delays in using the restroom can lead to bowel and urinary problems, such as constipation and urinary tract infection.
Many of the costs to the patient can also be measured and documented through use of the Cost Benefit Analysis.
Implement the solutions: Organizations should establish the program's infrastructure before implementing any educational component. This includes acquiring the lifting and transferring equipment and a clear plan about when to use it. Implementation should be unique to each organization, as it depends on supplementing components already in place. Perhaps additional lifting equipment is required, policies and procedures need to be updated, or subsequent training and education need to be supplied.
Regardless of the improvements made, organizations are encouraged to include employee representation from all levels of the program to endure their needs are met and to gain valuable insight and buy-in.
Follow-through: The same measures gathered in the initial program goal development phase, should be used to determine the success of the program. It requires ongoing monitoring and evaluation and incorporation of findings into new prevention strategies.  If measures are not producing the results identified in the goals according to the projected timeline, the program should be re-evaluated to determine appropriate corrective measures.
Few people would disagree that back injuries and other musculoskeletal disorders are a common and serious occurrence in patient care personnel. However, many also believe it is not possible to prevent such injuries and that the cost of prevention is greater than the cost of the injuries. However, with the advent of new technology, our current regulatory landscape, the increasing cost of workers' compensation, and the nursing shortage, this mindset is beginning to change. Someday soon, it is hoped that caregivers will be taking care of other people with back injuries, and will no longer need to worry about their own.

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