| TO: |
All Technical Writers. |
| FROM: |
The Fluid Power Safety Institute™. |
| SUBJECT: |
The FPSI™ needs your help! |
Introduction -
The modern era of fluid power began around the turn of the century.
In just a few decades, the industry has grown from 330 million dollars in 1945, to approximately 3 billion dollars in 1980. In 2000, the fluid power industry generated a staggering 12 billion dollars.
While these numbers confirm that the industry has experienced stunning growth from a commercial point of view, there is one key elements of the industry that has shown no signs of growth at all. In fact, one can say that it still lies within the industry's womb!
In 1966 an educational publications company introduced a comprehensive fluid power textbook to the industry. This textbook contained, amongst other things, instructions that were extremely hazardous for troubleshooting fluid power components.
The textbook was revised, enlarged, and completely rewritten in 1972. Yet the information about troubleshooting remained the same.
According to the publisher, thousands of these manuals have been sold to fluid power distributors, manufacturers, and educational institutions. The proliferation of this troubleshooting information has grown as impressively as the industry itself. Unfortunately, this textbook became the "standard" upon which much of what is written about component troubleshooting is based - and the rest is history!
In this, the dawn of a new millennium, instructions for "testing" fluid power components are written word-for-word out of the 1966 version of a textbook.
Apparently, no one has ever questioned the validity of the information. And what is more disappointing than that, no one seems to have ever edited the textbook for safety content!
Parts and pieces of the information contained in this "historic" manual can be found within the pages of the vast majority of troubleshooting manuals, which is evidence that it has become a key reference manual for technical writers throughout our nation.
There is also evidence that much of what individual manufacturers write about "testing" fluid power components seems to have been passed down from one generation of technical writers to another. Manuals that were written by manufacturers a decade ago have the same text and style as the ones that are currently produced.
One can only conclude that manufacturers are using a "cut and paste" approach to "updating" manuals, rather than updating the information, or at least verifying that the information is correct, and that the procedures are credible.
Tell me more! -
There are three vital elements that must be the fundamental basis of all technical writing - safety, liability, and accuracy:
| 1. |
Safety - |
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The first thing that any technical writer has to appreciate is, that much of what they write about is used to navigate people safely through hazardous situations - thus, people's lives lie in the palm of their hands!
Written instructions can either serve to guide them through their work safely and efficiently, or alternatively, lead them into a situation that could result in severe injury or death!
Here are a few tips about the safety issue:
| a. |
A safety committee or a hazard analysis committee MUST audit every written procedure and/or recommendation, regardless of how brief, for safety and accuracy. |
| b. |
The people on these committees MUST be competent - for example, an engineer should not be called upon to audit a test procedure that he or she has never personally undertaken.
Thus, a field repairperson, who has undergone theoretical and practical training, and has served an "apprenticeship" in the field, should be an integral component of the hazard analysis committee.
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| c. |
"CAUTIONS" and "WARNINGS" must be boldly posted (where necessary) throughout the instructions stating why there is a potential safety hazard. They must also include warnings about the consequences of failing to heed cautions and warnings. |
| d. |
Technical writers MUST contend with another element when writing for the fluid power industry: the majority of people who are going to use the information are going to be untrained.
Remember, training for people who work on and around fluid power systems, regardless of the complexity or associated hazards, is discretionary.
The problem of training is so chronic, that the FPSI™ strongly advises technical writers to assume that their audience is untrained.
This makes the need for well-conceived cautions and warnings absolutely critical to protect both the writer and the user.
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| 2. |
Liability - |
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Liability must take a back seat to safety. However, it is something companies must protect themselves against.
Our vision must never blur with respect to the safety and well being of people. We MUST do everything in our power to protect even those without proper training.
However, technical writers must also help to navigate their respective companies through the maze of liability that awaits them at every turn.
And, let us hasten to remind you, this issue is compounded by the fact that training in the fluid power industry is at the discretion of supervisors and managers.
Unlike electricity, "fluid power" has yet to be embraced by any safety organization including the American Society of Safety Engineers, OSHA, and MSHA, et al, as an occupational hazard.
This raises the bar with respect to the need for clear, well-defined, cautions and warnings.
Here are two directives technical writers MUST echo:
| a. |
"This/these procedures MUST be done by trained, authorized personnel only. If you are not trained and authorized, it/they could lead to severe injury or death." |
| b. |
"If you do not have the proper diagnostic instruments, DO NOT attempt this/these procedures. Failure to heed this warning could lead to severe injury or death." |
This language will help achieve a number of objectives:
| a. |
It is not the fault of our hardworking men and woman that they are not trained, it is the fault of their supervisors and managers. The language MUST therefore draw these people in as an accessory to an accident, so they can face due-process. |
| b. |
The majority of supervisors and managers view fluid power diagnostic equipment as an "unnecessary expense." This ideology forces people into unfair and unsafe "trial and error" work practices.
One of the chief goals of the FPSI™ is to get workers who are untrained, to refuse to do work on fluid power systems. Likewise, if they are trained, but do not have the proper diagnostic tools, they MUST refuse to do the work!
It is the view of the FPSI™ that having untrained and/or improperly equipped people work in hazardous situations without seeing to it that they are properly trained, is ethically and morally wrong! |
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| 3. |
Accuracy - |
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The information technical writers compile MUST be accurate - tried and proven methods only! Never forget that people are going to follow the prescribed recommendations, to the letter.
If they are led astray while following untried and unproven methods or recommendations, they could get severely injured or killed - we must not let this happen!
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Case history -
Here is just one example of the three aforementioned elements gone awry!
Unfortunately, we have many, many more!
This example is taken from a current "Operation and Test Manual" produced by one of the largest equipment manufacturers in the United States.
In the Safety Information section, which is appropriately placed in the front of the manual, there are a number of very bold warnings. One refers to fluid power, and it is titled: "Avoid high-pressure Fluids."
Quote: "Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source". End quote.
Another warning in the same manual titled: "Avoid Heating near Pressurized Fluid Lines."
Quote: " Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself or bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area." End quote.
Now let's turn our attention to the Hydraulic Section in the same manual, and turn to the instructions for the "Steering Valve Internal Leakage Test."
It shows an illustration of a steering valve to which the pump line remains connected, the "A" and "B" ports plugged, and the tank return line is disconnected, and wide open to atmosphere.
The illustration shows what appears to be a pipette (glass tube) at the mouth of the open port to catch, and measure, the leakage discharging from the open port.
FPSI™ Comment -
Let us imagine that some unknowing person is going to be perched in a precarious position on the subject machine, holding a pipette in one hand, while trying to turn the steering wheel with the other.
The first question one must ask is: "Why is this person executing this test?" The answer is simple: there is apparently something wrong with the steering system. In this case, a person MUST prepare for a "worst-case" scenario!
The manufacturer is now going to instruct the person to put a pressure drop across the valve of a staggering 3410 PSI (235 bar) (published steering pressure).
Summary: An untrained person, is going to hold a glass pipette within arms-length of a valve and literally "watch" what happens when 3410 PSI (235 bar) of hot hydraulic fluid is instantaneously applied to a port that is within inches of the open port.
It is highly likely that, due to the fact that the steering system is defective, the oil is going to discharge from the port at extreme velocity.
This "test" contradicts every one of this manufacturer's cautions and warnings, and leaves a person highly susceptible to severe injury or death.
When "testing" to atmosphere, there are additional factors that one must consider: If there is another machine parked alongside the disabled machine in the workshop, is it possible that the oil spray could come into contact with that machine's exhaust pipe or turbocharger?
It is a well-known fact that if oil is discharged under high pressure, an easily ignitable, fine oil mist will be sprayed over the surrounding area.
If this fine oil mist were to come into contact with the other machine's turbo-charger, or exhaust system, or perhaps, an overhead gas heater, it could result in a devastating fire.
On the other hand if the oil spray is confined within an engine compartment, a violent explosion can occur.
There are numerous additional tests within the subject manual that blatantly contradict the subject manufacturer's own cautions and warnings.
It is the opinion of the FPSI™, that this manufacturer has clearly overlooked the three key elements that are the fundamental basis for all technical writing:
| 1. |
Safety - |
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Any person executing these procedures is highly susceptible to a serious accident that could lead to severe injury or death.
In fact, one could argue that they are "safe," and yes, there is one condition under which they might offer a hint of safety - if the component is in perfect working order! If this were the case, why would one be conducting a test? |
| 2. |
Liability - |
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When a manufacturer warns a person about the consequences of doing unsafe procedures, and then advises them, within the covers of the same manual, to do it, it goes without saying that a jury will be merciless on the manufacturer. |
| 3. |
Accuracy - |
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The "tests" mentioned in the subject examples are erroneous. The majority of them can provide false positives. In other words, the test might indicate that the component is in good working condition when it is not, or visa-versa. |
What must be done to correct the problem?
| 1. |
It is the opinion of the FPSI™, that all technical writers should attend a course in basic fluid power to get acquainted with, and have a grasp of, the subject. |
| 2. |
Technical writers should attend a course in fluid power safety. |
| 3. |
Technical writers should, if possible, observe the task he or she is writing about. Ask questions about the procedure, note what special tools are being used, note what diagnostic instruments are being used, and most importantly, document worst-case scenarios.
For example: When documenting a pump test, and the test provides evidence that the pump is in good working condition, find out how the situation would have differed if the pump suffered severe internal leakage. |
| 4. |
If a manufacturer does not have a subject matter expert in-house to help technical writers compile reliable information, they should hire an outside consultant. |
| 5. |
Technical writers must get their information from the proper source. For engineering, seek the help of an engineer; for maintenance, seek the help of a maintenance professional, etc. |
| 6. |
Technical writers should pass their work on to the company's hazard analysis committee for review and approval. |
| 7. |
Technical manuals must have appropriate cautions and warnings. |
| 8. |
DO NOT offer substitutions for safe work - for example, if the job requires the skill of a qualified, competent, person, state this in bold type! If a special diagnostic instrument is required for the task, state this also in bold type!
Over 95% of the information that is written about testing fluid power systems condones the practice of discharging oil to atmosphere because manufacturers assume that the end-user does not have the proper tools, or, that they have the tools, but do not know how to use them.
Of course, there is one other consideration: the manufacturers themselves do not have, or know how to use, the proper tools!
Exhausting high-pressure oil to atmosphere is extraordinarily hazardous, AND SHOULD NEVER BE DONE!
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Conclusion -
Technical writers are the "midwives" - the people who can play a key role in delivering a critical, and much needed, element of the fluid power industry that has remained in the womb since the industry's inception - safety!
With the stroke of a pen, or the tapping of the keys on a keyboard, technical writers have the power to make the fluid power industry one of the safest industries in the world!
Let your will and determination to succeed in this endeavor be measured in direct proportion to your love for your fellow human being, your search for excellence, and your resolve to stand firm against compromise.
The Fluid Power Safety Institute™ stands ready to serve - we offer technical writers our full and unconditional support.
We urge every facet of this vast industry to join us in this exciting endeavor - to let safety reign! |
