conveyor safety
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ConveyorSafety
10-3-07
Frank J. Loeffler Jr.
Loeffler Engineering Group
STANDARDSSTANDARDS
OSHA 29 CFR 1910 & 1926.555OSHA 29 CFR 1910 & 1926.555 CEMA Belt Conveyor Handbook, Safety Labels 201 & CEMA Belt Conveyor Handbook, Safety Labels 201 &
Safety PosterSafety Poster ASME B20.1-1957ASME B20.1-1957 ASME B20.1-2006ASME B20.1-2006 ASME B15.1ASME B15.1 National Safety Council – Data Sheet 1-569National Safety Council – Data Sheet 1-569 ISO 5045-1979ISO 5045-1979 ANSI B11-TR3ANSI B11-TR3 ANSI Z535ANSI Z535 MSHA 30 CFR (For Mines)MSHA 30 CFR (For Mines) NFPA 654 Prevention of Fire & Dust ExplosionsNFPA 654 Prevention of Fire & Dust Explosions National Safety Council – Accident Prevention ManualNational Safety Council – Accident Prevention Manual Factory Mutual InsuranceFactory Mutual Insurance
OSHA 29 CFR 1910 Guards Walkways Floor Openings Training Lockout – Tagout Grain Elevators Marine Terminals Etc. www.OSHA.gov
Specifically references B20.1 1957 Edition
OSHA 1926.555
CEMACEMA
CEMA Safety LabelsCEMA Safety Labels
CEMA Safety LabelsCEMA Safety Labels
CEMA Safety PosterCEMA Safety Poster
Conveyor CrossoversConveyor Crossovers
Free Literature (CEMA)Free Literature (CEMA)
Safety Posters for Bulk Conveyors, Unit Safety Posters for Bulk Conveyors, Unit Conveyors, Bucket Elevators & Screw Conveyors, Bucket Elevators & Screw ConveyorsConveyors
Conveyor CrossoversConveyor Crossovers Safety Label Placement GuidesSafety Label Placement Guides
www.cemanet.orgwww.cemanet.org
Improper Design LoadsImproper Design Loads
ASME B20.1-1957 & 2006ASME B20.1-1957 & 2006
ASME B15.1ASME B15.1
Improper Belt Splice & Improper Belt Splice & Unguarded Unguarded
In-Running Nip PointIn-Running Nip Point
National Safety CouncilNational Safety Council
ISO 5045-1979ISO 5045-1979
ISO Conveyor Nip PointsISO Conveyor Nip Points
Nip PointsNip Points
Nip PointNip Point
Nip Point
Short Slider Bed
Opening to Nip Point
Tail Pulley Site of FatalTail Pulley Site of FatalCleaning AccidentCleaning Accident
ISO DistancesISO Distances
ANSI B11-TR3
ANSI Z535
Guard with Warning
MSHA 30 CFR Download from Internet
www.msha.gov
MSHA’s Guide to Guarding
Improper Guarding
Unguarded TU Bend Pulleys
In running Nip Point
MSHA Safety Tips
NFPA 654
Conveyor Fire
Petroleum Coke Shiploader Fire
National Safety Council - National Safety Council - ManualManual
Factory Mutual Conveyor Factory Mutual Conveyor SafetySafety
Factory Mutual Job Hazard Factory Mutual Job Hazard AnalysisAnalysis
Who Furnishes Safety Features Safety features must be reviewed by: Client Engineer Systems Integrator Manufacturer Installer
Injuries and Hazards that may be reduced by guards and Controls Pinch Points Material Falling Crushed Against
Objects Fall from Conveyors Reach Around Guards Servicing Moving
Conveyors
Fall Crossing Belts Fires Dust Explosions Toxic Dusts Electrical Shock
Cross Under / Over for Conveyors
Pinch Points Belt & Drive, Tail, Take-up or Bend Pulleys Idlers Under Skirtboards Troughing Idlers at Convex Curves Return Idlers (Accessible) Power Transmission Parts – ASME B15.1 Sweeps on Wheel / Rail
Guard Painting ANSI Z535 Warning Labels CEMA 201
Idler Guarded & Unguarded
Guards with Electrical Interlock
Common Causes of Accidents
Loose Clothing and Long Hair Applying Dressing to Pulley or Throwing Sand Cleaning Sticky Material from Belts or Pulleys on
a Moving Conveyor Cleaning Around or Under Conveyors Servicing Pulleys While Operating Removing Spilled Material from Return Belt Working Under Gravity Take-ups Adjusting Screw Take-ups
Fatal Nip Point Worker Threw Sand to Increase Pulley Traction
Take-ups
Screw – Extend Adjusting Screws beyond Guard Gravity- Guard Nip Points and Around
Counterweight Landing Area Hydraulic- Secure Stored Energy Automatic Take-ups Reduce Belt Slip
Take-Up Guard
Take-Up Cage
Holdbacks & Backstops
Use on Incline Conveyors Provide Means to Secure Belt & Load Inspection Under Load Size Based on Motor HP Brakes
Guards Against Falling Material
Conveyor Inclines Conveyors Passing Over Aisle, Passageway or
Workplace Enclosed Bottom & Sides Side Skirts Nets Enclosed Conveyors Hard Hat Area Signs
Idler That Can Pop Out and Fall
No Idler Retainer Clip
Falling Material Netting
Nets
Spillage @ Load Point
Guards Around Openings
OSHA Standards Define the Requirements for Floor and Wall Openings, Handrail, Platforms, Toe Boards, Confined Entry, and Escape Routes
OSHA 29 CFR 1910
Four Requirements For A Dust Explosion
• A Combustible Dust
• Dust Dispersion in Air or Other Oxidant At or Exceeding the Minimum Explosible Concentration (MEC)
• An Ignition Source
• Confinement
Fire & Explosion Prevention
Common Causes
Belt Slipping on Drive Pulley Belt or Pulley Rubbing Housing Frozen Rollers Bad Bearings Electrical Failures Static Electricity Tramp Iron in Conveyed Material Careless Heating of Frozen Material Inadequate Housekeeping
Fire & Explosion Prevention
Safeguards
MSHA Rated Conveyor Belt Automatic Take-ups, Special Lagging, Speed Switches Belt and/or Pulley Alignment Switches Inspect Bearings, Temperature & Vibration Detection Overload Devices (Do Not Bypass Protection Devices) Static Electricity Collectors & Grounding Metal Detectors and Magnets Collection or Suppression of Dust Cleanup Spillage that can Spontaneously Combust or
Create Dust Clouds Do not Overload Conveyors
Mistrained Belts
Belt Rubbing
Belt Rubbing
Grain Elevator Fires
Conveyor Control Systems
Nameplates on All Control Devices Provisions for Lockout / Tagout (LOTO) Conveyors not Visible from Control Point –
Visible or Audible Warnings with Time Delay Emergency Stop Cables Must be Installed on
Unguarded Conveyors Electrical or Mechanical Interlocking Overload or Plugged Chute Protection
Maintenance
Maintenance & Service shall be performed by Qualified and Trained Personnel
Equipment Must be Maintained in a Condition That is not Hazardous to Personnel
Maintenance and Service should be Performed With the Conveyor Locked Out and Tagged Out (OSHA 1910.147)
Only Trained and Qualified Personnel Who are Aware of Hazards of a Conveyor in Motion Shall be Allowed to Lubricate a Conveyor or Train a Belt While Equipment is in Operation.
Manuals
Manufacturer or Owner Shall Provide a Comprehensive Manual for the Care of All Equipment.
The Owner Shall Prepare a JSA (Job Safety Analyses) for all Maintenance and Repair Procedures.
Manuals Shall Include a Lockout / Tagout Procedure in Accordance with OSHA 1910.147
Manuals Shall Include an Instruction to Replace All Guards Before Restarting Equipment
ConclusionIt should be recognized that the application of the referenced standards listed herein may have divided responsibilities among the Owner, Management or Engineering Consultants, System Integrator, Manufacturer, Installer, Operator and User of the Conveyor or Conveyor System.
Some safety features are incorporated in the design of a conveyor, some will depend on the installation, some will depend on operation and some will be on the operator. Many safety features are a part of a building or structure and not an actual part of the conveyor or system itself. Yet other safety features are depending on rules and regulations set up by the operating company and/or local codes.
Thus, safety measures are the responsibility of all the parties involved in the contract. The portions of the standards relating to maintenance and operation are fully as important as those relating to design and installation.
Remember –
The Best of Design Features May be Negated by Faulty Maintenance and Operating Practices
Small Potato Conveyor
Switch to Reverse Conveyor
Transfer
Transfer
Think A Small Conveyor Cannot Cause Serious Injury ?
Think Again
And Large Conveyors can KILL
THE END
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