Conveyor Safety

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