© Chevron 2006© Chevron Rev. Aug. 2011

Portable Electric Grinder Safety

Manufacturing Standard GR - 150

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© Chevron 2006© Chevron Rev. Aug. 2011

Overview

Purpose

The purpose of this Mfg Standard is to protect personnel by specifying the requirements for portable grinders within the refinery

Objectives

This document is intended to highlight the safety precautions required for using portable electric grinders within the refinery. These precautions are to work in conjunction with industry standards, manufacturing standards, and established risk mitigation practices. The more stringent to apply.

Scope

This standard applies to employees and contractors alike whose work involves the use of portable electric grinders within the refinery.

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Portable grinders are one of the most potentially dangerous tools on any worksite. The majority of injuries associated with portable grinder use are foreign bodies in the eyes and lacerations to the body. These injuries typically result from one or more of the following items:

1.Improper selection of tools

2.Improper use or operation of the grinder

3.Failure to utilize the correct personal protective equipment

4. Improper abrasive/ grinding wheel selection

5.Incorrect body positioning and/or improperly inspected and maintained equipment

Procedures, Standards, and Guidelines

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1.Lock-off switch to prevent accidental starting of the portable grinder. The main operating trigger will automatically return to the OFF position when released. An unlocking action is required to start. The paddle switch shall not take up the length of grinder so that a good grip can be maintained when the start switch is released.

2.No lock-on switch to prevent the user from locking the grinder in the run position. Lock-on switches are not allowed.

3.Anti-kickback Clutch will disengage the rotating wheel from the motor when the wheel is pinched or a stall is detected. This reduces kick- back significantly.

4.Tool free adjustable guard protects from debris.

5.Quick disk change allows for tool free disk change of worn out disk.

6.Adjustable side handle allows for stability control of the grinder for right or left-handed users.

Required Safety Features for Portable Grinders

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1. A brake that allows for the rotating disk to stop rotating quickly once the trigger is released.

2. A soft start allows the disk to slowly ramp up preventing the jerk upon start up.

3. Vibration reducing features to improve ergonomics.

Grinder approval process

1. Chevron procurement will ensure that suppliers provide only those grinders that meet these requirements.

2. Contractors will ensure their employees use only approved grinders.

3. Chevron maintenance supervisors and projects reps are responsible for ensuring that only approved grinders are used on their jobs.

PPE Requirements

1. Standard PPE

2. A hard hat w/impact resistant face shield or welding hood will be worn whenever grinding.

3. Goggles or equivalent sealed eyewear will be worn under the face shield.

Desired but not required

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Safe Operation

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Daily Portable Grinder Visual Inspection

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Audits and Review

Maintenance Team Leaders and Chevron Contractor representatives are responsible for auditing adherence to this standard.

Exceptions

Exceptions to any part of this standard shall be issued and approved prior to work commencing.

The Chevron Maintenance Team Leader or Company Representative shall approve exceptions to this standard.

Portable Grinder Safety Awareness Training Requirements

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The following table outlines the roles and responsibilities associated with this process.Role Responsibilities

Chevron Maintenance Team Leader or Project Supervisor

Ensure the requirements of this standard are followed by performing frequent audits.

Approve any exceptions to this standard and ensure mitigation steps are in place to prevent injury.

Contractor site leadership

Ensure the requirements of this standard are understood and followed.

Ensure workers are trained on grinding and provide documentation that your company certifies each employee is capable of performing grinding work safely.

Roles and Responsibilities

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Role Responsibilities

Contractor site leadership Ensure workers are trained in the requirements of this standard.When required, issue exceptions to this standard with appropriate mitigation steps to ensure the job can be performed safely.

Mechanic (Chevron or Contract) Complete awareness training and fully understand the requirements of this standard.

Follow safe operating guidelines in this standard to ensure Incident and Injury Free work.

Roles and Responsibilities

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Roles Responsibilities

Mechanic (Chevron or Contract)

Perform daily inspections of the grinder per the requirements of this standard.

Review and follow the manufacturer’s documentation.

Procurement Ensure suppliers of portable grinders are aware of our requirements.

Ensure contractors understand our requirements for portable grinders.

Maintenance Training Department

Incorporate Grinder Safety Awareness standard into the Formal Maintenance Training Program. Ensure successful training.

Roles and Responsibilities

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Proposed Exception _____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Risk Mitigation ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Mechanics Assigned to use Portable Grinders with this Exception :

Print Name Date Print Name Date Print Name Date

Print Name Date Print Name Date Print Name Date

Print Name Date Print Name Date Print Name Date

Print Name Date Print Name Date Print Name Date

Approved: Yes NoChevron Maintenance Team Leader or Company Representative: Name: Name Date:

Portable Grinder Exception FormThis form shall be used to gain approval for any exception to GR-150, Portable Grinder Safety standard. Appropriate description of the proposed exception along with risk mitigation shall be clearly defined below. Any employee who is involved with this exception shall read and sign this form stating they fully understand the exception and risk mitigation steps. Company Name: __________________ Date____________________________Supervisor: ________________________Date: _______________________

© Chevron 2006Assess Analyze Actthe risk how to reduce the risk to ensure loss-free operation

Grinder Hazard Check ListBefore Use CheckYou are wearing your protective equipment including goggles/spoggles full face visor & dust mask (depending on material)Any work that is not part of a fixture should be securely clamped or held in a vice.Ensure the tool is in current PATCheck that the abrasive wheel is fitted correctly & securely, and that the guard is properly adjusted. Check disc is of correct rating for task.Ensure the handle is fitted as per manufacturers instructions.You can only change an abrasive wheel if you are trained to do so.Check that the abrasive wheel is clear of any obstruction before switching on.During UseBe prepared for large grinders to kick when starting up.Let the grinder run up to speed before contact with the work surface.Keep the wheel running at speed: if machine starts to labour and slow down do not force it so hard. Firm but steady.Use both hands to control the grinder on the correct handles.Lift the abrasive wheel clear of the work before switching off. The abrasive wheel will continue to rotate for a few seconds after switching off. Wait for it to stop before you put the grinder down.Switch off and stop work if someone approaches you.Watch out for signs of that vibration may be affecting your hands. If your fingers start to tingle or feel numb, take a short break from using the grinder. Exercise your fingers to encourage blood circulation.Make sure the machine ventilation slots do not become blocked with debris or dust.Keep the cable clear from the abrasive wheel and any sharp edges.If you think the cable may be cut or damaged in any way, switch off and unplug at the mains before inspecting it.Switch off and unplug before leaving the machine unattended.After UseSwitch off and isolate supplyClean the tool and work area.

PPE