Hustler Conveyor Company

Conveyor
Safety
Hustler Conveyor Company
ISRI DISCLAIMER The following presentation reflects the views and opinions of David Guyton and/or Mr. Guyton’s company, Hustler Conveyor Company. The content, views and opinions have not been reviewed or edited by ISRI and therefore should not be deemed to represent the views or opinions of ISRI or an endorsement of the material contained herein. You are permitted to reproduce the presentation contained herein, in whole or in part, without changing the text you use, provided that you include a copyright statement or "produced by David Guyton" statement, include this disclaimer on any portion of the material reproduced, and use the material or presentation for noncommercial or internal purposes only. For commercial use or translations, please contact the author directly. The single most important factor in the
prevention of accidents is a proper attitude
towards safety. It requires only little effort to
think about possible accidents and how to
prevent them. The habit of anticipating
potential accidents and how to prevent them
automatically prevents many of them from
occurring.
Safety First
With almost 10,000 conveyor accidents a year in
the United States, there is a heightened need to
provide conveyor safety on site. According to
the Bureau of Labor Statistics, powered
conveyors were the primary source of injury in
23 workplace fatalities in the past 8 years.
The leading cause of fatal accidents, is
employees trying to remove material sticking
to a roller or pulley while the belt is running.
In most fatal accidents belt speeds are
typically in the range of 150-400 feet per
minute. (FPM) or 2.5-6.5 feet per second.
It takes the average person 1 second to react
to an unexpected event.
That being said, even at 200 FPM, in that 1
second it takes that individual to react, the
belt has already moved 3 feet. Thus being far
enough to drag your tool, clothes, hair, or
limb into a dangerous area before you can
react.
Even though most injuries are not life
threatening, almost half result in lost work
time.
“Safety isn’t expensive, it’s priceless”
Personal Protective Equipment (PPE)
Proper Training
Safety Procedures
Safety Guards/Shields
Safety/Warning Signs
Operation/Maintenance Safety
“Personal Protective Equipment is Self Defense”
Hard Hat
Eye Protection
Hearing Protection
Safety Vest
Gloves
Steel Toe Boots
“Don’t learn safety by accident”
Everyone in the work place should be
well trained on all job specific Safety Procedures
Rules and Regulations
Equipment
Emergency Cut Off Switches
All maintenance, service, inspection, and
operating personnel must become familiar with
the operating controls, the inspection
procedures, and safety precautions applicable
for any conveyor system.
Always be prepared for emergencies. Learn
emergency precautions and be prepared to
execute them if necessary. Each worker has
an obligation to him/herself and his/her
fellow workers. All operating regulations
recommended by the manufacturer, the
employer. MUST BE FOLLOWED.
It is the owners responsibility to properly
train the personnel in conveyor operation
and maintenance, in order to provide
dependable safe service.
Give on-site instruction with the
conveyor system properly shut down.
Record the names of all employees that
were given instruction for safe
operations/maintenance, and fully
understand all precautions and safety
procedures.
As with most industrial accidents, lack of
training is the primary cause for conveyor
accidents. Regardless of the type of
equipment, failure to train employees is
still too often the source of serious
workplace injuries or fatalities. Material
handling accidents of all types account for
over 25% of all workplace accidents.
“Safety is a cheap and effective insurance policy”
Prior to performing
any maintenance the
conveyor and all
equipment directly
associated with it
including any moving
parts must be locked
and/or tagged out to
prevent inadvertent
activation.
Lock Out Procedures
DefinitionThe placement of the lock/tag on
the energy isolating device,
indicating that the energy-isolated
device shall not be operated until
removal of the lock/tag in
accordance with the established
procedure.
Lock Out Procedures
PurposeTo lock out all energy sources that
could cause injury to personnel.
Lock Out Procedures
Energy Isolating DeviceA physical device that prevents the
transmission of energy including, but
not limited to, the following: A
manually operated electrical circuit
breaker, a disconnect switch, and
similar devices with a visible
indication of the position of the
device.
Lock Out Procedures
Authorized IndividualsA knowledgeable individual to
whom the authority and
responsibility to perform a
specific assignment has been
given by employer.
Sequence of Lock Out Procedures
Notify all affected employees that a lock
out is to occur and the reason it is
required.
If the equipment is operating, shut it
down by the normal stopping
procedures.
Lock Out Procedures
Operate the switch, valve, or other
energy-isolated device so that all the
energy sources are disconnected or
isolated from the equipment.
Lock Out Procedures
Lock Out Procedures
Lock Out the
energy isolated
devices with an
assigned lock.
Lock Out Procedures
After ensuring that no personnel are
exposed, and as a test on having
disconnected the energy sources,
operate the push button, turn the
switches or other normal operating
controls to make certain the
equipment will not operate.
Lock Out Procedures
-CAUTIONReturn operating controls to neutral
position after the test.
-WARNINGNEVER under any circumstances
perform any maintenance or
inspection while the conveyor drive
motor is energized.
Restoring Equipment to Service
When the job is complete and
equipment is ready for testing or
normal service, check the equipment
area to see that no one is exposed, or in
a danger area. Also be sure all tools
and equipment are accounted for.
-WARNINGNEVER under any circumstance walk
on the conveyor while it is rotating or
while the conveyor motor is energized.
-WARNINGNEVER under any circumstance use
any conveyor for any purpose other
than that specified at the time of
original purchase from the
manufacturer as misapplication of this
machine can be dangerous to operating
personnel.
Lack of common sense, horseplay, and
taking short cuts contribute to
accidents. There have been incidents of
people being injured while being
transported on powered belt conveyors,
and getting loose clothing and long hair
caught in the system.
NEVER sit, walk, or ride on a
moving conveyor.
Designate and
enforce a safety
zone, the area in
which the
operator of the
equipment must
be while the
equipment is in
use.
When an employee
is around a below
grade conveyor it is
extremely important
to be aware of where
the pit starts. All pit
plates Must always
be in place when the
conveyor is in use or
energized.
Motors and
other electrical
equipment
must be
grounded.
A young worker was assisting a mechanic to align a running
conveyor belt. This task required that the belt be operated
intermittently, while small adjustments were completed. The
young worker walked into the area under the belt where the
lighting was poor and his movement was restricted. He put
his hand on the moving belt, which pulled his arm into the
area between the belt and adjustment roller. The mechanic
removed the adjustment roller to free the young worker's
fractured arm.
An investigation into this accident determined that the
location under the conveyor belt was not safeguarded and
that safe work practices for repairing the conveyor were not
provided.
“Safety doesn’t happen by accident”
As with many types of powered equipment;
lathes, presses, balers, and other machinery,
conveyor operators sometimes alter,
modify, or remove guards or other safety
devices specifically designed to protect
them and other coworkers to their
detriment. This is a major contributor to
conveyor accidents.
Point of operation guards must
prevent worker from having any part
of his/her body in the machines
danger zone during the operating
cycle.
Fixed shielding with
overhead protection
must be installed
when the operating
station is situated
near an overhead
hazard.
Power transmission
parts such as gears,
shafts, belts, or chains
must be guarded to
prevent accidental
contact.
When equipment is in operation all guards should be in place.
To prevent any
fingers, or any
other body parts
from being
injured the
opening on any
expanded metal
guards should be
no larger than 3/8
of an inch.
Visual and/or audible
warning signals must
be installed to warn of
impending start-up of
the conveyor. Such
warning devices must
provide at least 5
seconds of warning
before the machinery
begins to operate.
Where the vertical
distance between
walking or working
surfaces exceeds 4ft.
Railings or fall
protection equipment
must be utilized.
Safety cages on
ladders should
remain in place to
reduce the risk of
serious injury. It is
required to have a
safety cage if the
ladder height
exceeds 20 - 30
feet.
Check to see that no jammed objects
will damage or interfere with the
performance of the conveyors
All bolts and nuts should be checked
regularly. (approx. 40 operating hours)
After all inspections are made, all
safety guards and covers have to be
replaced and thoroughly secured.
A regular maintenance program should be
followed in order to obtain optimum
operation from the conveyor.
All areas under the conveyors should be
cleared of debris that would interfere with
the operation of the conveyor
TASK
DESCRIPTION
DAILY
WEEKLY
MONTHLY
BI-ANNUALLY
ANNUALLY
● INSPECTION
●
●
●
●
●
●
●
●
For Debris Around Shaft's & Pulley
Belts For Rips, Cuts, Tracking & Tension
Front / Back Seals & Skirt Seals
Wipers
Shaft Mount Reducer Drive Belt Tension
Guards In Place
Sprocket Setscrews
Look For Loose Bolts
X
X
X
X
X
X
X
X
● LUBRICATION
● Grease Bearings, Head, Tail, And Idlers
● Reducer Oil (30 Days Check For Metal)
● Reducer Oil (Change as Per Reducer Section
in Manual)
● Drive Sprocket Chain (Brush Lubricate)
● Oilers (10 Drops Per Minute)
● Motors
X
X
X
X
X
● TIGHTEN
●
●
●
●
●
●
Support Bolt's
Head Pulley (Check First Week)
Tail Pulley (Check First Week)
Drive Chain
Belt Chains (Roller Chain Belt & Steel Belt)
Belt Cleaner
●
●
●
●
●
●
●
●
Under Belt
In Pits
Sort Platform Area
Inside Guards
Around Self-Cleaning Tail Pulley
Around Safety Switches & Photo Eyes
Dirt Buildup On Return Roll
Around Belt Scraper
X
X
X
X
X
X
● CLEAN
X
X
X
X
X
X
X
X
X
Operators should be trained in safe
procedures for feeding a conveyor and
clearing a jammed conveyor.
Safely Clearing a clog or jamBefore attempting to clear a clogged or
jammed conveyor, the conveyor must
be de-energized, motion must be
stopped, and electrically locked out.
It is the responsibility of the owner to
electrically wire the conveyors through
a disconnect switch at all motor
locations.
When feeding a conveyor DO NOT
overload the conveyor. A moderate
steady feed of material ( not to exceed
side walls) will give the best overall
results providing optimum production
with safe results.
Loose clothing such
as hooded
sweatshirts, baggy
shirts or pants, illfitting gloves, or
unbuttoned sleeves
must never be
allowed in the
vicinity of operating
conveyors.
Long hair must be
fully contained before
any employee is
allowed to approach
moving conveyor
equipment.
When working on
or near conveyors,
pay close attention
to your posture.
Never lean way
out over a
conveyor because
you can easily lose
your balance and
fall onto the
conveyor.
Spill points are areas where
material can fall from an
overhead conveyor. To
protect workers below, spill
points are protected by spill
guards.
Shear points, sometimes called shear lines,
are areas where a moving part on a conveyor
meets or passes close to a stationary object.
Pinch points are the points between two
moving parts. They generally do not have
forward motion or rotation.
Nip points occur where two rotating parts
meet. These areas can nip, pinch, squeeze, or
entrap any object or body part that contacts
them.
Climbing over, down, or around
sorting chutes that are connected to
conveyor equipment is prohibited.
Sorters must be alerted prior to
moving sorting bins.
Provide emergency
stops that are easily
accessible from any
point along the
operating line.
Conveyors and
equipment they serve
should be interlocked,
such that by stopping
one, it automatically
stops the other.
All employees who work around conveyors need
to understand the location and operation of
emergency stop devices.
Emergency stops are only for emergencies and
should never be used to replace the lock out
procedure.
Sufficient safe
clearances must be
allowed between
machinery and
adjacent aisles and
passageways must
be clearly marked.
All personnel must
be aware of where
it is safe to walk.
NEVER under any condition, should
any person reach or look inside of the
drive guard while the conveyor motor
is energized or in motion.
All employees who work around conveyors
should be concerned about housekeeping. Keep
all areas around conveyors clean and clear of
clutter.
Never allow emergency stop devices to become
obscured or blocked by debris. These lifesaving
devices must be accessible at all times.
Luck runs out but safety is good for life
Personal Protective Equipment (PPE)
Proper Training
Safety Procedures
Safety Guards/Shields
Safety/Warning Signs
Operation/Maintenance Safety
Complacency Hurts
Occupational Safety and Health
Administration (OSHA)
American National Standards Institute
(ANSI)
Conveyor Equipment Manufacturers
Association (CEMA)
American Society of Mechanical Engineers
(ASME)
Bureau of Labor Statistics
Questions?