MACHINE GUARDING at BNL

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MACHINE GUARDINGat BNL
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CHALLENGES

• Implement OSHA Machine Guarding Requirements
• Manage Aging infrastructure (Includes Fabrication
  Equipment in Use)
• Competing Resources (Research vs. Support)
• Competing Concepts (I Know My Job vs. Show Me
  Your Process)
• Union Mentality/Concept (Us vs. Them)

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OSHA ASSESSMENT

• Audits Conducted In 2003
• Ten DOE Sites
• Driven By External Regulation Mandate

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OSHA STANDARD

• OSHA machine-guarding standard 29 CFR 1910,
  Subpart O, Machinery and Machine Guarding
• Performance Based
• Machine Safeguarding Decisions
• Engineering controls

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OSHA INTERPRETATION

• Point of operation hazard.
• Variable workplace circumstances
• Alternative Safeguarding Measures and Procedures

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BNL ASSESSMENT FINDINGS
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TOP 5 GUARDING ISSUES AT BNL

• 1910.219(d)(1)136 instances - Inadequate
  guarding pulleys 7 feet or less from floors
• 1910.212(a)(1)129 instances - Improper
  installation and use of machine guarding
• 1910.212(a)(3)(ii)61 instances - Improper point
  of operation guarding
• 1910.215(b)(9)36 instances - Inadequate grinder
  guarding
• 1910.212(b)35 instances - Inadequate anchoring
  of fixed machinery

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Implementation and Use of Interim Measures at BNL

• All Points of Operation to be Guarded
• Immediate LO/TO
• Exclusion Zones"
• Use of Hazard/Warning Signs
• Job Risk Assessments (JRAs)
• Toolbox training
• Skill of the Worker

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Machine Use At Central Fabrication Center
Requiring Job Risk Assessments (JRA)
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Failure of Machining Arbor in Heavy Machine Shop
At approximately 2230 hrs on Friday 8-8-03, a
machinist started to run a new batch on the Haas
Horizontal Machining Center. Unknown to him, a
programming error set the arbor spindle speed to
7500 (rotations per minute) RPM, rather than the
intended design speed of 750 RPM. When the mishap
was noticed The machinist heard the spindle
rotating at high speed and realized there was a
problem and immediately hit the EMERGENCY STOP
button. The spindle slowed down but before it
could stop completely, the arbor started to bend
then broke at the point where it was clamped into
the tool holder. The broken section of the
arbor and blades were projected upward striking a
structural, vertical I-beam approximately 11 ft.
away and 14 ft. above the floor. The piece
bounced off the I-beam, striking a second
horizontal structural member 2 ft. away and then
continued back parallel to the first path of
travel, striking the electrical panel of the
machining center and falling to the floor.(ORPS
CH-BH-BNL-BNL-2003-0012, Off-Normal Near Miss
Categorization)
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OTHER USEFUL REFERENCES

• http//www.sti.com/products/index.htm
• http//www.osha.gov/Publications/MachSafeGuard/toc
  .html
• Brauer, R. Safety and Health for Engineers. New
  YorkVan Nostrand Reinhold, 1990
• Kavianian, H. and C. Wentz. Occupational
  Environmental Safety Engineering and Management,
  Legislation, Regulations and Standards
• ANSI B-Series Standards B7.5 Abrasives,
• B11 - Machine Tools
• B15.1 - Power Transmission
• B173, Hand Tools
• B186.1, Portable Air Tools
• B209, Hand Tools
• B208, Pipe Threading Machines