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Accident Prevention Manual

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Accident Prevention Manual for Business & Industry: Engineering & Technology 13th edition National Safety Council Compiled by Dr. S.D. Allen Iske, Associate Professor – PowerPoint PPT presentation

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Title: Accident Prevention Manual


1
  • Accident Prevention Manual
  • for Business Industry
  • Engineering Technology
  • 13th edition
  • National Safety Council

Compiled by Dr. S.D. Allen Iske, Associate
Professor University of Central Missouri
2
CHAPTER 26
  • AUTOMATED LINES, SYSTEMS, OR PROCESSES

3
Automated Lines, Systems or Processes
  • Automation reduces labor costs, speeds up
    production, and can result in fewer errors.
  • Robots can work in environments hazardous to
    humans.
  • Robots can move heavy loads and do repetitive
    tasks.
  • Robots used in assembly, material handling, spray
    painting, and welding.
  • All computer-controlled processes can be
    considered automation.
  • Automation can resolve some safety hazards, but
    its incorporation can also present new safety
    challenges.

4
Automated Lines, Systems or Processes (Cont.)
  • Technicians can no longer understand the entire
    system.
  • Systems are now too complex and can have
    unintended interactions.
  • Safety gains can be cancelled out by increased
    speeds.
  • Engineers try to prevent accidents by reducing
    human control.
  • Failures in highly complex automated software
    programs responsible for controlling chemical
    reactions, inventories, maintenance activities,
    and schedules can be the root cause of serious
    accidents.

5
Manufacturing Philosophy
  • Many newer manufacturing philosophies deigned to
    enhance corporate competitiveness are only
    possible with the use of sophisticated automation
    run by computers.
  • Failures or software errors in these systems can
    result in serious adverse consequence.

6
Manufacturing Philosophy (Cont.)
  • Process safety management is a term initially
    applied to OSHAs 29CFR1910.119.
  • The standard only applies to processes which
    contain certain highly hazardous chemicals.
  • This systems engineering approach to managing
    hazards contains many management practices that
    are easily adopted for use on other systems.

7
Manufacturing Philosophies
  • Up-Front Planning for Safety
  • This philosophy requires management to include
    safety costs and design in all new equipment,
    construction, and installation.
  • Design-in Safety
  • Another up-front approach to automated safety.
    Requires that safety factors are a primary
    considerations during design process prior to
    purchase or modification of automated equipment.

8
Manufacturing Philosophies (Cont.)
  • Just-in-Time Methods
  • This method relies on manufacturing with reduced
    inventories and computerized scheduling which
    increases flexibility and reduces cost.
  • Computerized Maintenance Management
  • Equipment maintenance is managed through
    automation. Computers schedule maintenance and
    track repairs. Improves safety through predictive
    maintenance.

9
Hazard Identification and Controls
  • Guidelines
  • Careful identification of hazards during design,
    installation, and operation
  • Use of interlocking principles and devices where
    possible
  • Design that ensures maintenance issues can be
    addressed safely
  • Strategies developed to control the environment
    where the processes occur

10
Hazard Identification and Controls (Cont.)
  • Types of hazards
  • Hazards vary by industry.
  • Inhalation hazardsdusts and chemicals
  • Burn hazardshigh temperatures, acids, bases,
    steam
  • Radiation hazardsmicrowaves, gamma radiation for
    sterilization
  • Pinch hazardsmoving parts must be safeguarded
  • Explosions

11
Hazard Identification and Controls (Cont.)
  • Boundaries between restricted and non-restricted
    areas
  • Boundary that separates restricted work area from
    areas where workers can work safely
  • Envelope, maximumarea of maximum volume space
    for all robot part movements
  • Restricted envelopeportion of envelope to which
    robot is restricted by limiting devices
  • Operating envelopeportion of restricted envelope
    actually used by robot performing programmed
    motions

12
Hazard Identification and Controls (Cont.)
  • Visual and mechanical warnings
  • Warnings that alert workers to hazards
  • Includes signs, barriers, flashing lights, rails,
    lines on floor, or equivalent
  • Signs may need to be in several languages
    depending on the workforce.
  • International symbols may be necessary.
  • Workers need to be trained in the meaning of the
    various warning signs.
  • Audible warnings

13
Barriers and Interlocked Barriers
  • Hazard controls
  • Start and stop controls need to be accessible.
  • Robotic controls must be out of restricted area.
  • Awareness barriers are visual barriers that keep
    workers from reaching into hazards.
  • Perimeter barriers limit entrance into restricted
    areas.
  • Interlocks are safeguards in which the operation
    of one control automatically prevents another
    control from operating.

14
Barriers and Interlock Barriers (Cont.)
  • Maintenance and safety
  • Maintenance and repair personnel must be trained
    in safety procedures, hazard identification,
    specific equipment, regulatory standards.
  • Preventive maintenance helps supervisors
    anticipate downtimes in production.
  • Predictive maintenancemonitors machines,
    predicts failures reducing catastrophes.
  • Lockout/tagoutwritten procedures, protects
    workers from hazardous energy sources.
  • Various diagnostic aids and procedures help solve
    maintenance problems.

15
Automated Production
  • Automated materials handling and transport
  • Must be safeguarded because of pinch points and
    the potential for falling product
  • Conveyors, belts and hoistscontinuous transport
    of material to workstations
  • Automated guided vehicles (AGVs)vehicle path
    guided by electromagnetic wires, painted lines or
    chemical guides. Floors must be kept clean and
    dry and vehicle should have anti-collision device.

16
Robotic Equipment
  • Robotic Industries Association definition of
    robot is a reprogrammable multifunctional
    manipulator designed to move material, parts,
    tools, or specialized devices, through variable
    programmed motions for the performance of a
    variety of tasks.
  • handling devices with manual control
  • automated handling devices with cycles
  • programmable, servo-controlled robots with
    continuous point-to-point trajectories
  • robots capable of type C specifications, which
    also acquire information from the environment for
    intelligent motion.

17
Robotic Equipment (Cont.)
  • Robots have three major components
  • Manipulatorrobotic arm (base through wrist)
    working in the operating envelope
  • Power supplypneumatic, hydraulic or electric
  • Control system
  • Non-servo control point-to-point typepick and
    place material applications
  • Servo-control point-to-point typeload and unload
    product
  • Servo-control continuous typespray painting and
    finishing operations

18
Hazards of Robotics
  • Hazards within operating envelope
  • Hazards exist within reach of a robots arm.
  • Accidents occur when robots start or move
    unexpectedly, drop objects, or human error.
  • Safeguarding robots3 categories
  • Safety in the process of manufacturing,
    remanufacturing, and rebuilding robots
  • Installation of robots
  • Safeguarding of workers exposed to hazards
    associated with the use of robots

19
Hazards of Robotics (Cont.)
  • Safeguarding personnel
  • Robot teacherguides robot through its motions
    which are memorized by a computer. This presents
    the greatest danger to workers.
  • Robot operatormust be protected from robot
    movements in the restricted envelope.
  • Maintenance/repair personnelmust use
    lockout/tagout procedures operations and any
    modifications of robotic tasks.

20
Hazards of Robotics (Cont.)
  • Computer-integrated controls
  • Many robots are controlled by computer programs.
  • Lack of standardization among manufacturers and
    varying human-system interfaces represents a
    safety challenge to safety managers.

21
Chemical Processes
  • Process safety information
  • Chemical processes have many hazards such as
    inhalation and explosion hazards.
  • Managers must detail hazard information through
    written safety policies, engineering and
    administrative controls, worker training, and
    PPE.
  • One method is the facility Chemical Process
    Document (CPD). The CPD is a sort of cook book
    which has all of the safety parameters for the
    safe operation of a facility.

22
Chemical Processes (Cont.)
  • General information in a CPD
  • assessment of hazards of materials
  • toxicity information
  • permissible exposure limits
  • physical data
  • thermal/chemical stability data
  • reactivity data
  • corrosivity data
  • hazardous effects of inadvertently mixed chemicals

23
Chemical Processes (Cont.)
  • Design information in a CPD
  • block flow diagrams or simplified process flow
    diagrams
  • process chemistry
  • maximum needed inventory
  • acceptable upper and lower limits for items such
    as temperatures, pressures, flows, and
    compositions

24
Chemical Processes (Cont.)
  • Mechanical design information in a CPD
  • piping and instrument diagrams, electrical area
    classifications, and relief systems
  • design in ventilation system
  • equipment and piping specifications and
    description of the shutdown and interlock systems
  • design codes employed
  • required or mandatory inspections and maintenance
    activities

25
Chemical Processes (Cont.)
  • Hazards and risk analysis
  • Safety personnel must ask THREE Whats
  • What can go wrong?
  • What is the probability that something will go
    wrong?
  • What would be the consequences if something does
    go wrong?

26
Hazards/Risk Analysis
  • Hazard identification methods
  • hazard surveys
  • process checklists
  • hazard and operability studies (HAZOP)
  • safety reviews
  • formal
  • informal

27
Hazard/Risk Analysis (Cont.)
  • Other methods
  • what if? analysis
  • failure mode, effects, and criticality analysis
    (FMECA)
  • fault tree analysis (FTA)
  • event tree analysis (ETA)
  • human error analysis
  • Timing
  • begins early in the process and remains ongoing

28
Chemical Processes and Elements of Process
Safety Management
  • Risk assessment usually has four components
  • What potentially catastrophic incidents could
    possibly occur?
  • What is the downwind dispersion likely to be in
    the event of a toxic gas release?
  • What would the impact be on the workplace and
    community?
  • Can we quantify or conduct a probability analysis
    for incidence occurrence?

29
Chemical Processes
  • Pre-startup reviews
  • All elements of a process safety management
    program should be in place and running before
    beginning the warm-up or startup phase of a
    facility operation.
  • Reviews should be updated every 310 years.
  • High substance hazard index value or large
    quantities of toxic, flammable, or explosive
    substances
  • Proximity to a populous area or large work force.
  • Severe operating conditions that can cause
    corrosion or explosion.

30
Chemical Processes (Cont.)
  • Operating procedure manual
  • Manual that details rules and guidelines for safe
    operation of the facility
  • position of the person responsible for each
    facility areas
  • clear instructions for safe operations
  • operating conditions and steps for initial
    start-up
  • normal, temporary, and emergency operations
  • normal shutdown
  • start-up following a turnaround
  • operating limits (safety considerations apply)
  • descriptions of consequences of deviation
  • steps to correct or avoid deviations
  • safety systems and their functions
  • occupational safety/health considerations

31
Chemical Processes (Cont.)
  • Management of change
  • Changes in technology can impact the workplace
    and the work environment.
  • Managers must analyze these changes and how they
    affect safety, operations, and processes.
  • Additional training may be required.

32
Auditing
  • Audits pinpoint deficiencies in safety and
    processes caused by factors such as changes in
    personnel or priorities.
  • Audits should be conducted every 35 years.
  • Auditing of process safety management is a line
    responsibility.
  • Outside and inside audits are important and
    beneficial.
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