MACHINE SAFEGUARDINGMACHINE SAFEGUARDING

Safeguarding a mechanical Safeguarding a mechanical equipment and machinery has equipment and machinery has always been of great importance in always been of great importance in any serious effort to reduce or any serious effort to reduce or eliminate occupational injuries.eliminate occupational injuries.

IntroductionIntroduction

Crushed hands and arms, severed fingers, blindness - the list of possible machinery-related injuries is as long as it is horrifying. Safeguards are essential for protecting workers from needless and preventable injuries.

A good rule to remember is: Any machine part, function, or process which may cause injury must be safeguarded.

Where the operation of a machine can injure the operator or other workers, the hazard must be controlled or eliminated.

MachineMachine Safety Safety

This man lost his This man lost his finger when a machine finger when a machine in a foundry cut it off.in a foundry cut it off.

There was no guard in There was no guard in place, as required by place, as required by law, to keep his finger law, to keep his finger out of a point of out of a point of contact.contact.

BASIC PRINCIPLEBASIC PRINCIPLE

1.1. Engineer the hazard out of the job.Engineer the hazard out of the job.

2.2. Guard the hazard.Guard the hazard.

3.3. Educate personnel to maintain a Educate personnel to maintain a healthy respect for guards.healthy respect for guards.

Engineer Hazards Out of the JobEngineer Hazards Out of the Job

The following principles can be appliedThe following principles can be applied1.1. Allow sufficient space for easy Allow sufficient space for easy

maintenance and repair.maintenance and repair.

2.2. Mark off machine areas.Mark off machine areas.

3.3. Locate machines properly and provide Locate machines properly and provide substantial railings.substantial railings.

Guard the HazardGuard the Hazard

Prevent injury from these sources:Prevent injury from these sources:

1.1. Direct contact with moving parts of Direct contact with moving parts of machine.machine.

2.2. Work processes.Work processes.

3.3. Mechanical failure.Mechanical failure.

4.4. Electrical failureElectrical failure

5.5. Human failure resulting from; curiosity, Human failure resulting from; curiosity, zeal, distraction, fatigue, chance taking, zeal, distraction, fatigue, chance taking, etc.etc.

Educate EmployeesEducate Employees

Safe practices require that;Safe practices require that;1.1. No machine should be started unless No machine should be started unless

guards are in place.guards are in place.2.2. No guards should be removed or adjusted No guards should be removed or adjusted

unless necessary.unless necessary.3.3. Whenever guards are removed the power Whenever guards are removed the power

should be turned off and the main switch should be turned off and the main switch locked or tagged.locked or tagged.

4.4. Loose clothing, necktie, or long hair Loose clothing, necktie, or long hair should never be worn around moving should never be worn around moving machinery.machinery.

Types of Mechanical MotionTypes of Mechanical Motion

1.1. RotaryRotary

2.2. ReciprocatingReciprocating

3.3. OscillatingOscillating

Where Guards are NeededWhere Guards are Needed

1.1. Power transmission apparatus/equipmentPower transmission apparatus/equipment

2.2. Moving partsMoving parts

3.3. Point of operationPoint of operation

Nov. 2, 2003 Rig Floor

Running at 130 rpm

Causes of Machine AccidentsCauses of Machine Accidents

Reaching in to “clear” equipmentReaching in to “clear” equipment Not using Lockout/TagoutNot using Lockout/Tagout Unauthorized persons doing Unauthorized persons doing

maintenance or using the machinesmaintenance or using the machines Missing or loose machine guardsMissing or loose machine guards

Where Mechanical Hazards OccurWhere Mechanical Hazards Occur

Point of operationPoint of operation All parts of the machine which move, such as:All parts of the machine which move, such as:

flywheels, pulleys, belts, couplings, chains, cranks, flywheels, pulleys, belts, couplings, chains, cranks, gears, etc.gears, etc.

feed mechanisms and auxiliary parts of the machinefeed mechanisms and auxiliary parts of the machine In-running nip pointsIn-running nip points

Point of OperationPoint of Operation

That point where work is performed on the material, such as cutting, shaping, boring, or forming of stock must be guarded.

Rotating PartsRotating Parts

In-Running Nip PointsIn-Running Nip Points

Power-Transmission ApparatusPower-Transmission Apparatus

Power-transmission apparatus (shafting, flywheels, pulleys, belts, chain drives, etc.) less than 7 feet from the floor or working platform must be guarded.

Unguarded beltand pulley

Types of GuardingTypes of Guarding

Can be group into the following:Can be group into the following:

1.1. Guards for rotational motion.Guards for rotational motion.

2.2. Guards for nip points.Guards for nip points.

3.3. Guards for cutting shearing mechanism.Guards for cutting shearing mechanism.

4.4. Guards for punching and forming mechanismGuards for punching and forming mechanism

Fixed GuardFixed Guard

Provides a barrier - a permanent part of the machine, preferable to all other types of guards.

Interlocked GuardInterlocked GuardWhen 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.

Interlocked guard on revolving drum

Adjustable GuardAdjustable Guard

Provides a barrier which may be adjusted to facilitate a variety of production operations.

Bandsaw blade adjustable guard

Self-Adjusting GuardSelf-Adjusting Guard

Provides a barrier which moves according to the size of the stock entering the danger area.

Circular table saw self-adjusting guard

Pullback DevicePullback Device

Utilizes a series of cables Utilizes a series of cables attached to the operator’s attached to the operator’s hands, wrists, and/or armshands, wrists, and/or arms

Primarily used on machines Primarily used on machines with stroking actionwith stroking action

Allows access to the point of Allows access to the point of operation when the slide/ram operation when the slide/ram is upis up

Withdraws hands when the Withdraws hands when the slide/ram begins to descendslide/ram begins to descend

Pullback Device Pullback Device (cont’d)(cont’d)

Hands in die, feedingHands in die, feeding Point of operation exposedPoint of operation exposed Pullback device attached Pullback device attached

and properly adjustedand properly adjusted

Die closedDie closed Hands withdrawn from Hands withdrawn from

point of operation by point of operation by pullback devicepullback device

Restraint DeviceRestraint Device

Uses cables or straps attached Uses cables or straps attached to the operator’s hands and a to the operator’s hands and a fixed pointfixed point

Must be adjusted to let the Must be adjusted to let the operator’s hands travel within operator’s hands travel within a predetermined safe areaa predetermined safe area

Hand-feeding tools are often Hand-feeding tools are often necessary if the operation necessary if the operation involves placing material into involves placing material into the danger areathe danger area

Safety Tripwire CablesSafety Tripwire Cables

Device located Device located around the around the perimeter of or near perimeter of or near the danger areathe danger area

Operator must be Operator must be able to reach the able to reach the cable to stop the cable to stop the machinemachine

Two-Hand ControlTwo-Hand Control

.

Requires constant, Requires constant, concurrent pressure to concurrent pressure to activate the machineactivate the machine

The operator’s hands are The operator’s hands are required to be at a safe required to be at a safe location (on control location (on control buttons) and at a safe buttons) and at a safe distance from the danger distance from the danger area while the machine area while the machine completes its closing cyclecompletes its closing cycle

Safeguarding by Safeguarding by Location/DistanceLocation/Distance

Locate the machine or its dangerous Locate the machine or its dangerous moving parts so that they are not moving parts so that they are not accessible or do not present a hazard accessible or do not present a hazard to a worker during normal operationto a worker during normal operation

Maintain a safe distance from the Maintain a safe distance from the danger areadanger area

Guard ConstructionGuard Construction

1.1. FixedFixed

2.2. InterlockingInterlocking

3.3. AutomaticAutomatic

Interlocking Guards requirementsInterlocking Guards requirements

a.a. It must guard the dangerous part before It must guard the dangerous part before the machine can be operated.the machine can be operated.

b.b. It must stay closed until the dangerous It must stay closed until the dangerous part is at rest.part is at rest.

c.c. It must prevent operation of the machine It must prevent operation of the machine if the device fail or is damage.if the device fail or is damage.

Training Training

Hazards associated with particular machinesHazards associated with particular machines How the safeguards provide protection and the hazards How the safeguards provide protection and the hazards

for which they are intendedfor which they are intended How and why to use the safeguards How and why to use the safeguards How and when safeguards can be removed and by How and when safeguards can be removed and by

whom whom What to do if a safeguard is damaged, missing, or What to do if a safeguard is damaged, missing, or

unable to provide adequate protectionunable to provide adequate protection

Operators should receive training on the following:

SummarySummary

Safeguards are essential for protecting workers Safeguards are essential for protecting workers from needless and preventable machinery-related from needless and preventable machinery-related injuriesinjuries

The point of operation, as well as all parts of the The point of operation, as well as all parts of the machine that move while the machine is working, machine that move while the machine is working, must be safeguardedmust be safeguarded

A good rule to remember is: A good rule to remember is: Any machine part, Any machine part, function, or process which may cause injury must function, or process which may cause injury must be safeguardedbe safeguarded

Don’t let this happen to you…………

Lockout/Tagout Lockout/Tagout

LockoutLockout

Lockout is a technique used to prevent the Lockout is a technique used to prevent the release of hazardous energy, or to prevent the release of hazardous energy, or to prevent the hazardous energy from escaping.hazardous energy from escaping.

A padlock is placed on the appropriate energy A padlock is placed on the appropriate energy isolating device that is in the off or closed isolating device that is in the off or closed position.position.

DefinitionsDefinitions Authorized Employee - one who locks out machines Authorized Employee - one who locks out machines

or equipment in order to perform the servicing or or equipment in order to perform the servicing or maintenance on that machine or equipment.maintenance on that machine or equipment.

Affected Employee - one whose job requires him/her Affected Employee - one whose job requires him/her to operate or use a machine or equipment on which to operate or use a machine or equipment on which servicing or maintenance is being performed under servicing or maintenance is being performed under lockout, or whose job requires him/her to work in an lockout, or whose job requires him/her to work in an area in which such servicing or maintenance is being area in which such servicing or maintenance is being performed.performed.

Definitions, cont.Definitions, cont. Energy Isolating Device - A mechanical device Energy Isolating Device - A mechanical device

that physically prevents the transmission or that physically prevents the transmission or release of energy.release of energy.

Energy Control Procedure - Safety program Energy Control Procedure - Safety program adopted by the employer that includes energy adopted by the employer that includes energy control procedures plus provisions for control procedures plus provisions for inspecting the procedures and training inspecting the procedures and training employees for lockout/tagout.employees for lockout/tagout.

Types of Lockout DevicesTypes of Lockout Devices Plug LocksPlug Locks Ball Valve LockoutBall Valve Lockout Gate Valve LockoutGate Valve Lockout Group Lockout HaspGroup Lockout Hasp

ElectricalElectrical Hydraulic, pneumatic, Hydraulic, pneumatic,

and other pressurized and other pressurized systemssystems

Types of Lockout DevicesTypes of Lockout Devices

Types of Lockout DevicesTypes of Lockout Devices

Types of Lockout DevicesTypes of Lockout Devices

Types of Lockout DevicesTypes of Lockout Devices

Types of Lockout DevicesTypes of Lockout Devices

                                                        

                                                        

Step 1:Step 1:Verify circuit breaker is de-energized. Place Verify circuit breaker is de-energized. Place PSL-CBL lockout device over breaker with PSL-CBL lockout device over breaker with the handle centered in lockout opening.the handle centered in lockout opening.

Step 2:Step 2:Turn the toggle set screw knob and tighten Turn the toggle set screw knob and tighten firmly against the breaker handle.firmly against the breaker handle.

                                                        

Step 3:Step 3:Rotate and flip toggle set screw upwards.Rotate and flip toggle set screw upwards.

Step 4:Step 4:Install lock and tag and test for security. Install lock and tag and test for security. Verify that the lockout device secures the Verify that the lockout device secures the disconnect in a safe or off position.disconnect in a safe or off position.

Types of Lockout DevicesTypes of Lockout Devices

Lockout ProcedureLockout Procedure Alert the operator (s) that power is being Alert the operator (s) that power is being

disconnected.disconnected. Preparation for ShutdownPreparation for Shutdown Equipment ShutdownEquipment Shutdown Equipment IsolationEquipment Isolation Application of Lockout DevicesApplication of Lockout Devices Control of Stored EnergyControl of Stored Energy Equipment Isolation-VerificationEquipment Isolation-Verification

Removal of LockoutRemoval of Lockout Ensure equipment is safe to operateEnsure equipment is safe to operate Safeguard all employeesSafeguard all employees Remove lockout/tagout devices. Except in Remove lockout/tagout devices. Except in

emergencies, each device must be emergencies, each device must be removed by removed by the person who put it on.the person who put it on.

Last person to take off lockLast person to take off lock Follow checklistFollow checklist

Temporarily Reactivating Temporarily Reactivating EquipmentEquipment

Remove unnecessary tools from the work area Remove unnecessary tools from the work area and make sure everyone is clear of the and make sure everyone is clear of the equipmentequipment

Remove lockout/tagout devices and re-Remove lockout/tagout devices and re-energize the systemenergize the system

As soon as the energy is no longer needed, As soon as the energy is no longer needed, isolate the equipment and re-apply isolate the equipment and re-apply lockout/tagout, using the six step procedure.lockout/tagout, using the six step procedure.

Tidbits of Info.Tidbits of Info. Never attempt lockout/tagout procedures unless you Never attempt lockout/tagout procedures unless you

have been trained and certified by your employer have been trained and certified by your employer under an approved Energy Control Program.under an approved Energy Control Program.

Never loan or share your lock, combination, or key Never loan or share your lock, combination, or key with anybody else.with anybody else.

Always be sure all lockout/tagout devices are Always be sure all lockout/tagout devices are compatible with the environment in which they will compatible with the environment in which they will be used i.e. corrosive, humid, etc.be used i.e. corrosive, humid, etc.

Any Questions?Any Questions?