Mining%20and%20Petroleum%20Training%20Service

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Mining and Petroleum Training Service Basics
of Equipment Guarding Presented by David
Spann Presentation Developed by Rene Azzara
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Basics of Machine Safeguarding Crushed hands
and arms, severed fingers, blindness - the list
of possible machinery-related injuries is as
long as it is horrifying. There seem to be as
many hazards created by moving machine parts as
there are types of machines. Safeguards are
essential for protecting workers from needless
and preventable injuries.
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A good rule to remember is Any machine part,
function, or process which many cause injury
must be safeguarded. When the operation of a
machine or accidental contact with it can injure
the operator or others in the vicinity, the
hazards must be either controlled or eliminated.
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• Tolerable Risk
• "risk that is accepted for a given task and
  hazard combination"
• - as described in ANSI B11.TR3

Following an organized and logical approach, risk
assessment and risk reduction can achieve a
tolerable risk.
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• Risk Assessment Process

Gather Equipment Specifications
Determine Equipment Limitations
Identify Equipment Hazards and Task Hazards
Use Limitations Space Limitations Time
Limitations Environment Limitations Interface
Limitations
Estimate Risk Probability Determine Whether
Risk Is Tolerable
Catastrophic Permanent Disabling Serious Severe
Disabling Moderate Significant Disabling Minor
Sligh Disabling
Very Likely to Occur Likely, May Occur Unlikely,
Not Likely to Occur Remote Very Unlikely
If Untolerable, Risk Reduction Measures Must Be
Implemented
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Hazard Reduction Activities
Supportive
Use PPE
Incorporate Administrative Controls
Incorporate Safeguarding Technologies
Eliminate and Reduce Hazards by Design
Primary
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• Where to begin
• Know how to use the machine safely before
  operating.
• Have you reviewed the owner's manual? It will
  provide
• operating, repairing, lubricating and fuel
  information.
• Are the Warning Decals in place?
• Are the machine guards properly placed and in
  good condition?
• Are electrical lines damage free?
• Are air and hydraulic lines in good condition
  and not leaking?
• Is the setup a proper setup?
• Is the area around the machines orderly?

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• Safety begins before you
• even start the equipment!
• Personal Protection
• Wear PPE, such as goggles, safety shoes
• and leather gloves.
• Long hair should be tied back or tucked
• under to avoid getting caught in machinery.
• Avoid wearing jewelry.

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Machine Maintenance Checklist for Safety Keep
machines repaired, lubricated and adjusted.
Clean up excess lubricants. Clearly mark
control switches and valves that control
machines. Check machines for emergency stop
switches they should be located on or near the
machine so the machine can be turned off quickly
if a malfunction occurs.
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Where Mechanical Hazards Occur
Dangerous moving parts in three basic areas
require safeguarding
Power transmission apparatus All components of
the mechanical system which transmit energy to
the part of the machine performing the work.
These components include flywheels, pulleys,
belts, connecting rods, couplings, cams,
spindles, chains, cranks, and gears.
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Other moving parts All parts of the machine which
move while the machine is working. These can
include reciprocating, rotating, and transverse
moving parts, as well as feed mechanisms and
auxiliary parts of the machine.
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The Point of Operation The point where work is
performed on the material, such as cutting,
shaping, boring, or forming of stock.
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• Hazardous Mechanical Motions and Actions
• The basic types of hazardous mechanical motions
  and actions are
• Motions
• rotating (including in-running nip points)
• reciprocating
• transversing
• Actions
• cutting
• punching
• shearing
• bending

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Warnings and training are least effective
because people will always make mistakes!
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Some guards are designed based on hand speed
The human hand can move at 63 inches per
second! Example A device located 2 inches from
a grinder must be able to sense the hand and
stop the grinder in under 0.03 seconds.
T2(in)/63(in/s).032s
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Types of guarding devices

• Presence Sensing (photo electric light curtain)
• Pullback - Restraint - Gates or Covers
• Safety Controls
• Others distance and automatic systems

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Be Aware of Nip Points Hazardous spots where
loose clothing or body parts could be caught and
squeezed in rotating parts. All pulleys, belts,
sprockets and chains, flywheels, shafting and
shaft projections, gears, and couplings, or other
rotating or reciprocating parts.
If it moves, it merits your attention!
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• Nip Points
• Rotating Dangers
• clothing
• jewelry
• hair
• body parts

Do not wear gloves around reciprocating or
rotating machine parts.
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Note A nip point entry permit system is intended
for observation of hazardous machinery while at
a safe distance. It is not a "Permit to Work" in
a nip point zone. Permit to Work activity must
only be undertaken with the machine shut down
and locked out.
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• Protecting Hands and Fingers Guide
• Identify the pinch points on mechanically moved
  loads, lowered loads and metal drums.
• Know when to wear gloves. Sometimes gloves can
  present a danger!
• Allow rotating parts to come to a stop before
  working on them.
• Use a tapered punch or other appropriate tool
  to align the holes in parts.
• Rings should not be worn when operating or
  repairing machinery.
• Remove fuses with fuse removers, not fingers.
• Do not test the temperatures of gases, liquids,
  or solids with hands. Reflex damage can
• occur immediately.
• Keep grinder tool rests adjusted to 1/8 inch
  gap or less.
• Handle sharp or pointed tools (hatchets,
  chisels, punches, awls, knives, pitch forks and
• machine blades) carefully.
• Perform maintenance only when tools or
  machinery are not in operation.
• If guards are removed to perform maintenance,
  replace immediately after servicing.

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Reciprocating motions may be hazardous because,
during the back-and-forth or up-and-down motion,
a worker may be struck by or caught between a
moving and a stationary part.
Transverse motion (movement in a straight,
continuous line) creates a hazard because a
worker may be struck or caught in a pinch or
shear point by the moving part.
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More Safety Considerations Never step across a
rotating power shaft. Equipment operators should
wear close-fitting clothes and slip-resistant
footwear. Rotating parts catch loose clothing
easily. Never allow children around the
equipment or work area.
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Machinery Maintenance and Repair Good
maintenance and repair procedures contribute
significantly to the safety of the maintenance
crew as well as that of machine operators. In
addition to guarding, you need to understand
LOTO - Lockout/Tagout (aka) CHE - Control of
Hazardous Energy
In shops where several maintenance persons might
be working on the same machine, multiple lockout
devices accommodating several padlocks are used.
The machine cannot be reactivated until each
person removes his or her lock. As a matter of
general policy, lockout control is gained by the
procedure of issuing personal padlocks to each
maintenance or repair person no one but that
person can remove the padlock, thereby each
worker controls the power systems.
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• Whenever machines or equipment are serviced,
• there are hazards encountered by the employees
• performing the servicing or maintenance which are
  
• unique to the repair or maintenanceprocedures
  being
• conducted.
• These hazards may exist due to the failure of the
  
• employees doing the servicing or maintenance to
  stop
• the machine being worked on.
• Even if the machine has been stopped, the machine
  
• can still be hazardous due to the possibility of
  the
• machine becoming reenergized or restarting.

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Guards Guards are barriers which prevent
access to dangerous areas. There are four
general types of guards
Fixed - A fixed guard is a permanent part of the
machine. Interlocked - When this type of guard
is opened or removed, the tripping mechanism
and/or power automatically shuts off or
disengages, and the machine cannot cycle or be
started until the guard is back in place.
Adjustable - Adjustable guards are useful
because they allow flexibility in accommodating
various sizes of stock. Self-Adjusting - The
openings of these barriers are determined by the
movement of the stock. Self-adjusting guards
offer different degrees of protection.
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Guard Construction Today many builders of
single-purpose machines provide
point-of-operation and power transmission
safeguards as standard equipment. However, not
all machines in use have built-in safeguards
provided by the manufacturer!
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• Guards designed and installed by the builder
  offer
• two main advantages
• They usually conform to the design and function
  of the
• machine.
• They can be designed to strengthen the machine
  in some
• way or to serve some additional functional
  purposes.

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• Be wary of older
• equipment!
• Inspect older equipment, and if
• necessary upgrade machinery to
• current standards.
• Lock out or block moving machinery
• against motion before working nearby
• unless all pulleys and pinch points
• are guarded or located where persons
• can not contact them.
• Guard pinch points on conveyor
• pulleys
• Establish and enforce policies that
• prohibit work or travel near
• unguarded machinery components.

A conveyor attendant with 5 years mining
experience was fatally injured at an open pit
copper operation. The victim became entangled in
a tripper conveyor pulley.
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• User-built guards are sometimes necessary for a
  variety
• of reasons. They have these advantages
• Often, with older machinery, they are the only
  practical safeguarding solution.
• They may be the only choice for mechanical power
  transmission apparatus in older plants, where
  machinery is not powered by individual motor
  drives.
• They permit options for point-of-operation
  safeguards when skilled personnel design and make
  them.
• They can be designed and built to fit unique and
  even changing situations.
• They can be installed on individual dies and
  feeding mechanisms.
• Design and installation of machine safeguards by
  plant personnel can help to promote safety
  consciousness in the workplace.

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• User-built guards also have
• disadvantages
• User-built guards may not conform well to the
  configuration and function of the machine.
• There is a risk that user-built guards may be
  poorly designed or built.
• Intended to be installed at some point, yet never
  were.

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• Additional considerations when building
• a guard
• Does the design, construction, selection of
  materials and guard installation prevent contact
  with all moving machine part hazards?
• Does the guard provide protection by itself,and
  not rely on visual or tactile awareness of a
  hazard, administrative controls or procedures
  such as warnings, signs, lights, training,
  supervision or PPE?
• Are the guard materials, fastening methods, and
  construction suitable to withstand the wear,
  corrosion, vibration and shock of normal
  operations?
• If drive belts inside a guard fail, will the
  whipping action of broken belts be contained?
• Is the guard recognizable as a guard?
• Is the guard installed securely?

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• Ergonomic Considerations of Machine Safeguarding
• Consider worker stress and fatigue when
  designing.
• Employees may defeat guarding if it is difficult
  to remove and
• replace easily.
• Design Considerations
• Lightweight, without being flimsy
• Can be handled by one person
• Access doors or tops
• Guards with rollers or wheels
• Screen that allows operator visual access also
  allows operator to rinse off machinery
• Design so hands and tools cannot fit thru screen

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Machine Safety Responsibilities

• Management
• Ensure all machinery is properly guarded
• Supervisors
• Train employees on specific guard rules in
• their areas Ensure machine guards
• remain in place and are functional
• Immediately correct machine guard
• deficiencies
• Employees
• Do not remove guards unless machine is
• locked and tagged Report machine guard
• problems to supervisors immediately
• Do not operate equipment unless
• guards are in place

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Proper training should address

• Hazards associated with particular machines
• How the safeguards provide protection and the
  hazards for which they are intended
• How and why to use the safeguards
• How and when safeguards can be removed and by
  whom
• What to do if a safeguard is damaged, missing, or
  unable to provide adequate protection

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• Deaths attributed to
• Inadequate Guarding
• from MSHA files

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On July 21, 2005, a 31-year old plant operator
with two years mining experience was fatally
injured at a sand and gravel operation. The
victim made a splice on a conveyor belt and was
making adjustments to the belt.
He was found entangled in the tail pulley of
the conveyor.
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On February 7, 2002, a 37-year-old male laborer
(the victim) was fatally injured when he became
caught between a conveyor belt and an idler
pulley of a rock crushing machine. The victim's
job consisted of sweeping and shoveling the area
around the rock-crushing machine. Approximately
20 minutes after the victim arrived at work he
was found underneath the rock crushing machine
with his arm caught between a conveyor belt and
an idler pulley.
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• The victim was caught by one of the rock crushing
  machine's conveyor belts and
• an idler pulley. The location of the victim was
  underneath the machine near the
• electrical panel.

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What steps did the investigator note that
should have been taken that would
have prevented this fatality?

• Hazard analysis of equipment prior to use.
• Employee task training.
• Proper guarding.
• Installation of pull cable emergency stops that
  surrounds the entire
• machine's perimeter instead of intermittently
  placed push buttons.

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Trip cable accessible to operator
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Does the idler present a significant hazard? Is
a person likely to get close to the idler roller
face? Is the nip point directly accessible?
No
Yes
No
Yes
No
Yes
An effective guard is required
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• On June 17, 2005, a 32-year-old equipment
  operator/mechanic with
• 5 years mining experience was fatally injured at
  a sand and gravel
• operation. The victim was removing toggle seat
  wedge bolts so
• that the broken pitman toggle seat could be
  replaced.

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The safety pins, provided by the manufacturer
- had not been installed - no steps had
been taken to block/secure this component
against hazardous motion.
The pitman assembly shifted and fatally pinned
the victim against the crusher framework.
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On November 23, 2003, a 44-year-old company vice
president with 2 years mining experience was
fatally injured at a crushed stone operation.
The victim was using a steel bar to dislodge a
blockage in an impact crusher. The bar contacted
a moving crusher component causing it to be
propelled and strike the victim's neck. The
accident occurred because the procedures used to
dislodge the blockage of rock were inadequate.
Deadly Force Impact
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When the blockage occurred, the victim failed to
deenergize and lock out the crusher before
attempting to dislodge the rock.
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Lesson Deenergize and lockout equipment. Never
attempt to remove jammed material while machinery
is in operation. Shut down, isolate, and block
all forms of hazardous energy before performing
machine maintenance. Do not allow employees to
position themselves directly over the intake of a
horizontal impactor while it is actively crushing
rock. Viewing decks should be designed and
installed where worker's can safely access the
equipment to observe operation.
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The worker had reversed his truck up to the
primary hopper in order to discharge a load of
quarried material. He then walked to the rear of
his truck, before falling into the hopper. In
order to discharge the load, it was not necessary
to leave the truck. It is unknown why the driver
did so.
Nothing can protect you from senseless acts.
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Lock out before servicing As he was oiling a
moving conveyor, a worker's pant leg became
entangled in the part of the conveyor, causing
his right foot to be dragged in and crushed
between the head sprocket and the side of the
conveyor. His right leg had to be amputated
below his knee. The worker usually oiled the
conveyor from a relatively safe position from
underneath the conveyor. For some reason, on
this day, he decided to oil the conveyor from
an unstable position above the conveyor without
locking out. His pant legs also hung down
below his boots.
Lesson Follow task procedures every time!
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Work safely around guardrails A machine tender
was found pinned in the ingoing nip point of a
press. He died from massive crush injuries.
There was no witness to this accident.
Guardrails were in place around the machine. It
is unclear how the victim fell into the nip point
of the press. He may have been reaching into or
over top of one of the guardrails.
Lesson Never reach through or over top of a
guardrail of any machinery.
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Safe work practices Do not defeat guards and
place body parts, tools or pry bars in
equipment that is not deenergized or LOTO.
Develop and follow written procedures for
checking the well-being of a worker working
alone or in isolation, including
establishingcontact at predetermined intervals
and at the end of the shift.
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Best Practices

• Ensure that miners receive task training prior to
  allowing them to perform maintenance or repair on
  machinery or equipment.
• Discuss the work procedures, including all
  possible hazards ( Risk Assessment ) and ensure
  the manufacturer's recommendations are followed
  for all repair work.
• Before working on equipment, lock-out the power
  and block equipment components against all
  possible motion/movement resulting from a sudden
  release of energy.
• Make sure you have the proper AUTHORITY to
  deenergize or lock-out equipment before
  proceeding. Shutting off power may shut down
  production in other areas and create safety
  hazards to unsuspecting individuals.
• If potential hazards or prescribed procedures are
  unclear, DO NOT proceed until all safety concerns
  are adequately resolved.

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Now we will watch the DVD
MSHA's
Junkyard Guards