Industrial Safety and Health for Goods and Materials Services - Chapter 23 pptx

When using compressed air for cleaning, employees should wear protective chip guarding eyewear and personal protective equipment.. 23.2 CONTROL OF HAZARDOUS ENERGY SOURCES LOCKOUT=TAGOUT

23 Other Hazards

The retail, wholesale, and warehousing sectors are the sectors that handle, store, and disperse the largest quantities of goods and materials in the United States Since all the potential hazards faced by these three sectors cannot be addressed in detail in one book it may be necessary to use Industrial Safety and Health for Infrastructure Services, Industrial Safety and Health for Administrative Services, and Industrial Safety and Health for People-Oriented Services to address other hazards This chapter provides summaries regarding some of the other common hazards that confront workers in these sectors Some of these hazards are also covered in some detail in the other three books mentioned above

Some of the hazards that were not covered extensively in this book are

as follows:

. Compressed air

. Lockout=tagout

. Dockboards

. Electrical

. Fueling

. Powered tools

. Scaffolds

. Tire inflation

. Workplace violence

Tire inflation and repair can be deadly (Courtesy of Mine Safety and Health Administration.)

23.1 COMPRESSORS AND COMPRESSED AIR (29 CFR 1910.242)

A compressor supplies compressed air Great care must be taken to ensure such types

of equipment are operating safely Safety devices for a compressed air system should

be checked frequently Compressors should be equipped with pressure relief valves and pressure gauges

The air intakes must be installed and equipped so as to ensure that only clean uncontaminated air enters the compressor This is facilitated by the installation of air filters on the compressor intake

Before any repair work is done on the pressure system of a compressor, the pressure is to be bled off and the system locked out All compressors must be operated and lubricated in accordance with the manufacturer’s recommendations Signs are to be posted to warn of the automatic starting feature of compressors The belt drive system is to be totally enclosed to provide protection from any contact

No worker should direct compressed air toward a person, and employees are prohibited from using highly compressed air for cleaning purposes If compressed air

is used for cleaning clothes, the pressure is to be reduced to less than 10 psi When using compressed air for cleaning, employees should wear protective chip guarding eyewear and personal protective equipment

Safety chains or other suitable locking devices are to be used at couplings of high pressure hose lines where a connection failure would create a hazard Before compressed air is used to empty containers of liquid, the safe working pressure of the container is to be checked

When compressed air is used with abrasive blast cleaning equipment, the operat-ing valve type must be held open manually When compressed air is used to inflate auto tires, a clip-on chuck and an inline regulator preset to 40 psi are required Compressed air should not be used to clean up or move combustible dust because such action could cause the dust to be suspended in the air and cause afire or explosion hazard

23.2 CONTROL OF HAZARDOUS ENERGY SOURCES

(LOCKOUT=TAGOUT) (29 CFR 1910.147)

Lockout=tagout deals with the preventing of the release of energy from machines, equipment, and electrical circuits which are perceived to be de-energized The Occupational Safety and Health Administration (OSHA) estimates compliance with the lockout=tagout standard will prevent about 120 fatalities and approximately 28,000 serious and 32,000 minor injuries every year About 39 million general industry workers will be protected from accidents during maintenance and servicing

of equipment under this ruling

The standard for the control of hazardous energy sources (lockout=tagout) covers servicing and maintenance of machines and equipment in which the unexpected energization or startup of the machines or equipment or release of stored energy could cause injury to employees The rule generally requires that energy sources for equipment be turned off or disconnected and that the switch either be locked or labeled with a warning tag About 3 million workers actually servicing equipment face the greatest risk These include craft workers, machine operators, and laborers

OSHA’s data show that packaging and wrapping equipment, printing presses, and conveyors account for a high proportion of the accidents associated with lock-out=tagout failures

Typical injuries include fractures, lacerations, contusions, amputations, and puncture wounds with the average lost time for injuries running 24 days Agriculture, maritime, and construction employers are not covered under standard 29 CFR 1910.147 Also, the generation, transmission, and distribution of electric power by utilities and work on electric conductors and equipment are excluded The general requirements for the ruling require employers to

. Develop an energy control program.

. Use locks when equipment can be locked out (Figure 23.1).

. Ensure that new equipment or overhauled equipment can accommodate

locks

. Employ additional means to ensure safety, when tags rather than locks are

used by using an effective tagout program

. Identify and implement specific procedures (generally in writing) for the control of hazardous energy including preparation for shutdown, shutdown,

FIGURE 23.1 Locking out a plug on a saw

equipment isolation, lockout=tagout application, release of stored energy, and verification of isolation

. Institute procedures for release of lockout=tagout including machine inspec-tion, notification and safe positioning of employees, and removal of the lockout=tagout device

. Obtain standardized locks and tags which indicate the identity of the

employee using them and which are of sufficient quality and durability to ensure their effectiveness

. Require that each lockout=tagout device be removed by the employee who applied the device

. Conduct inspections of energy control procedures at least once a year. . Train employees in the specific energy control procedures with training reminders as part of the annual inspections of the control procedures

. Adopt procedures to ensure safety when equipment must be tested during

servicing, when outside contractors are working at the site, when a multiple lockout is needed for a crew servicing equipment, and when shifts or personnel change

Excluded from coverage are normal production operations including repetitive, routine minor adjustments which would be covered under OSHA’s machine guard-ing standards Work on cord and plug connected electric equipment when it is unplugged, and the employee working on the equipment has complete control of the plug Hot tap operations involving gas, steam, water, or petroleum products when the employer shows that continuity of service is essential, shutdown is impractical, and documented procedures are followed to provide proven effective protection for employees

In summary all machinery or equipment capable of movement is required to be de-energized or disengaged and locked out during cleaning, servicing, adjusting, or setting up operations, whenever required Where the power disconnecting means for equipment does not also disconnect the electrical control circuit, the appropriate electrical enclosures must be identified A means should be provided to assure the control circuit can also be disconnected and locked out The locking out of control circuits in lieu of locking out main power disconnects must be prohibited All equipment control valve handles are to be provided with a means for locking out Lock-out procedures require that stored energy (mechanical, hydraulic, air, etc.) be released or blocked before equipment is locked out for repairs Appropriate employees must be provided with individually keyed personal safety locks and are expected to keep personal control of their keys while they use safety locks Only the employee exposed to the hazard should place or remove the safety lock Employees must check the safety of the lock out by attempting a startup after making sure no one is exposed Employees need to be instructed to always push the control circuit stop button immediately after checking the safety of the lock out A means is to be provided to identify any or all employees who are working on locked-out equipment

by their locks or accompanying tags A sufficient number of accident preventive signs or tags and safety padlocks need to be provided for any reasonably foreseeable repair emergency When machine operations, configuration, or size requires the

operator to leave his=her contr ol station to install tools or perfor m other operations , and that part of the machine could move if accide ntally activated, that element is required to be separa ted, locked, or blocke d out In the event that equipm ent or lines cannot be shut down , locked out, and tagged , a safe job procedu re is to be estab lished and rigidly followed

23.3 DOCKBOARDS (29 CFR 1910.30)

Dockboards are to be strong enough to carry the load imp osed up on them (See Figure 23.2) Portab le dockboar ds a re to be anchore d or equipped wi th device s that will prevent their slipping Handholds shoul d exist on dockboa rds which provide a safe and effect ive means of handlin g Railr oad cars shoul d be provided with a mechanism that would prevent movem ent while dockboar ds a re being used

23.4 ELECTRICAL (29 CFR 1910.303, 304, 305, 331, AND 333)

Electrici ty is accepted as a source of powe r without much though t to the hazards encountered So me empl oyees work with electrici ty direc tly, as is the case with engineers, elect ricians, or p eople who do wiring , such as overhea d lines, cable harnesses, or circuit assemblies Others, such as office workers and salespeople, work with it indirectly Approximately 700 workers are electrocuted every year with many wor kers suffe ring injuries such as burns, cuts, etc (Figur e 23.3)

FIGURE 23.2 Example of dockboards or plates for loading a trailer at a dock

OSHA’s electrical standards address the government’s concern that electricity has long been recognized as a serious workplace hazard, exposing employees to such dangers as electric shock, electrocution,fires, and explosions The objective of the standards is to minimize such potential hazards by specifying design characteristics

of safety in use of electrical equipment and systems

Electrical equipment must be free from recognized hazards that are likely to cause death or serious physical harm to employees Flexible cords and cables (extension cords) should be protected from accidental damage Unless specifically permitted flexible cords and cables should not be used as a substitute for the fixed wiring of a structure, where attached to building surfaces, where concealed or where they run through holes in walls, ceilings, or floors, or where they run through doorways, windows, or similar openings Flexible cords are to be connected to devices and fittings so that strain relief is provided that will prevent pull from being directly transmitted to joints or terminal screws

A grounding electrode conductor is to be used for a grounding system to connect both the equipment grounding conductor and the grounded circuit conductor to the grounding electrode Both the equipment grounding conductor and the grounding electrode conductor are to be connected to the ground circuit conductor on the supply side of the service disconnecting means or on the supply side of the system disconnect-ing means or overcurrent devices if the system is separately derived For ungrounded service-supplied systems, the equipment grounding conductor should be connected to the grounding electrode conductor at the service equipment The path to ground from circuits, equipment, and enclosures should be permanent and continuous

Electrical equipment should be free from recognized hazards that are likely to cause death or serious physical harm Each disconnecting means should be legibly FIGURE 23.3 Electrical exposure is common in most service sector businesses (Courtesy of Mine Safety and Health Administration.)

marked to indicate its purpose, unless the purpose is evident Listed or labeled equipment should be used or installed in accordance with any instructions included

in the listing or labeling Unused openings in cabinets, boxes, and fittings must be effectively closed

Safety-related work practices are to be employed to prevent electric shock or other related injuries resulting from either direct or indirect electrical contacts, when work is performed near or on equipment of circuits that are or may be energized Electrical safety-related work practices cover both qualified persons (those who have training in avoiding the electrical hazards of working on or near exposed energized parts) and unqualified persons (those with little or no such training)

There must be written lockout and=or tagout procedures Overhead power lines must be de-energized and grounded by the owner or operator of the lines, or other protective measures must be provided before starting work Protective measures, such as guarding or insulating the lines, must be designed to prevent employees from contacting the lines

Unqualified employees and mechanical equipment must be at least 10 ft away from overhead power lines If the voltage exceeds 50,000 V, the clearance distance should be increased 4 in for each 10,000 V

OSHA requires portable ladders to have nonconductive side rails if used by employees who would be working where they might contact exposed energized circuit parts

Conductors are to be spliced or joined with devices identified for such use or by brazing, welding, or soldering with a fusible alloy or metal All splices, joints, and free ends of conductors should be covered with an insulation equivalent to that of the conductor or with an insulating device suitable for the purpose

All employees should immediately report any obvious hazard to life or property observed in connection with electrical equipment or lines Employees need to be instructed to make preliminary inspections and=or appropriate tests to determine what conditions exist before starting work on electrical equipment or lines

All portable electrical tools and equipment are to be grounded or of double insulated type Electrical appliances such as vacuum cleaners, polishers, and vending machines must be grounded Extension cords being used are to have a grounding conductor and multiple plug adapters are prohibited

Ground-fault circuit interrupters should be installed on each temporary 15 or 20 A,

120 V AC circuit at locations where construction, demolition, modifications, alterations, or excavations are being performed All temporary circuits are to be protected by suitable disconnecting switches or plug connectors at the junction with permanent wiring If electrical installations in hazardous dust or vapor areas exist, they need to meet the National Electrical Code (NEC) for hazardous locations

In wet or damp locations, the electrical tools and equipment must be appropriate for this use or all location or otherwise protected The location of electrical power lines and cables (overhead, underground, under thefloor, other side of walls) are to

be determined before digging, drilling, or similar work is begun

All energized parts of electrical circuits and equipment are to be guarded against accidental contact by approved cabinets or enclosures, and sufficient access and

working space must be provided and maintained about all electrical equipment to permit ready and safe operations and maintenance

Low-voltage protection is to be provided in the control device of motors driving machines or equipment which could cause probable injury from inadvertent starting Each motor disconnecting switch or circuit breaker should be located within sight

of the motor control device and each motor located within sight of its controller Employees who regularly work on or around energized electrical equipment or lines should be instructed in the cardiopulmonary resuscitation (CPR) methods

23.5 FUELING

An internal combustion engine should not be fueled with aflammable liquid while the engine is running Fueling operations are to be done in such a manner that likelihood of spillage will be minimal

When spillage occurs during fueling operations, the spilled fuel is to be washed away completely, evaporated, or other measures taken to control vapors before restarting the engine Fuel tank caps are to be replaced and secured before starting the engine

Fueling hoses are to be of a type designed to handle the specific type of fuel It is prohibited to handle or transfer gasoline in open containers No open lights, open flames, sparking, or arcing equipment are allowed during fueling or transfer of fuel operations and no smoking should be permitted

23.6 PORTABLE (POWER-OPERATED) TOOLS AND EQUIPMENT (29 CFR 1910.243)

Tools are such a common part of our lives that it is difficult to remember that they may pose hazards All tools are manufactured with safety in mind but, tragically, a serious accident often occurs before steps are taken to search out and avoid or eliminate tool-related hazards In the process of removing or avoiding the hazards, workers must learn to recognize the hazards associated with the different types of tools and the safety precautions necessary to prevent those hazards All hazards involved in the use of powered tools can be prevented by following five basic safety rules:

. Keep all tools in good condition with regular maintenance.

. Use the right tool for the job.

. Examine each tool for damage before use.

. Operate according to the manufacturer’s instructions

. Provide and use the proper protective equipment.

Employees and employers have a responsibility to work together to establish safe working procedures If a hazardous situation is encountered, it should be brought to the attention of the proper individual immediately

Powered tools can be hazardous when improperly used There are several types

of powered tools, based on the power source they use: electric, pneumatic, liquid fuel, hydraulic, and powder-actuated Employees should be trained in the use of all tools—not just powered tools They should understand the potential hazards as well

as the safety precautions to prevent those hazards from occurring The following general precautions should be observed by powered tool users:

. Never carry a tool by the cord or hose.

. Never yank the cord or the hose to disconnect it from the receptacle.

. Keep cords and hoses away from heat, oil, and sharp edges.

. Disconnect tools when not in use, before servicing, and when changing

accessories such as blades, bits, and cutters

. All observers should be kept at a safe distance away from the work area. . Secure work with clamps or a vise, freeing both hands to operate the tool. . Avoid accidental starting The worker should not hold afinger on the switch button while carrying a plugged-in tool

. Tools should be maintained with care They should be kept sharp and clean

for the best performance Follow instructions in the user’s manual for lubricating and changing accessories

. Be sure to keep good footing and maintain good balance.

. The proper apparel should be worn Loose clothing, ties, or jewelry can get

entangled in moving parts

. All portable electric tools that are damaged should be removed from use

and tagged‘‘Do Not Use.’’

Hazardous moving parts of a powered tool need to be safeguarded For example, belts, gears, shafts, pulleys, sprockets, spindles, drums, flywheels, chains, or other reciprocating, rotating, or moving parts of equipment must be guarded if such parts are exposed to contact by employees Guards, as necessary, should be provided to protect the operator and others from the following:

. Point of operation

. In-running nip points

. Rotating parts

. Flying chips and sparks

Safety guards must never be removed when a tool is being used For example, portable circular saws must be equipped with guards An upper guard must cover the entire blade of the saw A retractable lower guard must cover the teeth of the saw, except when it makes contact with the work material The lower guard must automatically return to the covering position when the tool is not being used The following handheld powered tools must be equipped with a momentary contact‘‘on–off’’ control switch: drills, tappers, fastener drivers, horizontal, vertical and angle grinders with wheels larger than 2 in in diameter, disk and belt sanders, reciprocating saws, saber saws, and other similar tools These tools may also be

equipped with a lock-on control provided so that turnoff can be accomplished by a single motion of the samefinger or fingers that turn it on

The following handheld powered tools may be equipped with only a positive

‘‘on–off’’ control switch: platen sanders, disk sanders with disks 2 in or less in diameter, grinders with wheels 2 in or less in diameter, routers, planers, laminate trimmers, nibblers, shears, scroll saws, and jigsaws with blade shanks 0.25 in wide

or less

Other handheld powered tools such as circular saws having a blade diameter greater than 2 in., chain saws, and percussion tools without positive accessory holding means must be equipped with a constant pressure switch that will shut off the power when the pressure is released

Employees using electric tools must be aware of several dangers; the most serious being the possibility of electrocution Among the chief hazards of electric-powered tools are burns and slight shocks which can lead to injuries or even heart failure Under certain conditions, even a small amount of current can result in fibrillation of the heart and eventual death A shock also can cause the user to fall off a ladder or other elevated work surfaces

To protect the user from shock, tools must either be grounded, double insu-lated, or powered by a low-voltage isolation transformer Three-wire cords contain two current-carrying conductors and a grounding conductor One end of the grounding conductor connects to the tool’s metal housing The other end is grounded through a prong on the plug Anytime an adapter is used to accommodate

a two-hole receptacle, the adapter wire must be attached to a known ground The third prong should never be removed from the plug Double insulation is more convenient The user and the tools are protected in two ways: by normal insulation

on the wires inside, and by a housing that cannot conduct electricity to the operator

in the event of a malfunction These general practices should be followed when using electric tools:

. Electric tools should be operated within their design limitations.

. Gloves and safety footwear are recommended during use of electric tools. . When not in use, tools should be stored in a dry place.

. Electric tools should not be used in damp or wet conditions.

. Work areas should be well lighted.

Powered abrasive grinding, cutting, polishing, and wire buffing wheels create special safety problems because they may throw off flying fragments Before an abrasive wheel is mounted, it should be inspected closely and sound- or ring-tested to be sure that it is free from cracks or defects To test, wheels should be tapped gently with a light nonmetallic instrument If the wheel sounds cracked or dead, it couldfly apart

in operation and so must not be used A sound and undamaged wheel will give a clear metallic tone or‘‘ring.’’ To prevent the wheel from cracking, the user should be sure itfits freely on the spindle The spindle nut must be tight enough to hold the wheel in place, without distorting the flange Follow the manufacturer’s recom-mendations It must be ensured that the spindle wheel does not exceed the abrasive wheel specifications Due to the possibility of a wheel disintegrating (exploding)