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Grinder Use Safety Training. Nov 2005 Grinders are dangerous tools that can cause severe injuries or even death. safestGrinders should be chosen for the.

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Presentation on theme: "Grinder Use Safety Training. Nov 2005 Grinders are dangerous tools that can cause severe injuries or even death. safestGrinders should be chosen for the."— Presentation transcript:

1 Grinder Use Safety Training

2 Nov 2005 Grinders are dangerous tools that can cause severe injuries or even death. safestGrinders should be chosen for the reason of performing the job in the safest manner first and saving time last. Use other tools when the associated inherent hazards are less severe. The following slides explain the Freeport site’s expectations regarding grinder use and some general hazards and precautions. In case of a discrepancy between this presentation and the manufacturer’s recommendations, the manufacturer’s recommendations take precedence. Introduction

3 Nov 2005 A training course, including a practical test, must be completed successfully by every person who uses a grinder. A practical test must be successfully completed once every 24 months Any unsafe use will result in suspension of permission to use grinders. Freeport Grinder Use Training Requirements

4 May 20104 Grinder Related Injuries Grinders have contributed to fatalities! On December 12, 2005, a 30-year old man died from blood loss after his leg was cut by an angle grinder. On January 11, 2006, a grinding disk spun off a grinder and struck a person in the kneecap. Stitches were required. In March of 2008 a contractor was struck in the neck when a grinder kicked back resulting in 30 stitches.

5 May 20105 Most Recent Grinder Injuries Grinders have contributed to fatalities! February 13, 2010 – Oyster Creek, Texas – While waiting for the grinder to power down, the individual’s wrist came in contact with the grinding wheel requiring 20 stitches. March 22, 2010 – Deer Park, Texas – A grinding wheel came apart and struck the individual's arm requiring 7 stitches. Freeport is taking measures to achieve the vision of an injury-free workplace.

6 May 20106 What are the Common Hazards of Grinder Use? High speed flying particles … a grinding wheel’s speed can be greater than a mile a minute –from the grinding wheel itself –from the work piece being ground Inhaling dust and fumes generated Explosion or fire –if sparks ignite flammable or combustible materials nearby or below grinding operation Electric shock from frayed or defective power cord Noise Musculoskeletal disorders (MSDs) from –repetitive use –awkward body positions

7 May 20107 Common Causes of Grinding Incidents Using the wrong wheel for the job or grinder Improper mounting of wheel or guard Careless handling Repetitive motion Improper PPE use Improper use of grinder

8 May 20108 Critical Grinder Wheel Safety Issues Some Grinding wheels can be surprisingly delicate. They can be easily damaged if handled carelessly. –Store new wheels carefully in a dry area close to the grinding operation. –When you have to carry one, do it very carefully. –Take special care not to drop it or to bump it against anything. –Never use a wheel that has been dropped or received a heavy blow, even if there is no apparent damage. –Replace wheels that are badly worn or cracked.

9 May 20109 Using the Right Wheel Ensure the wheel is designed for the machine’s size and speed and the material of construction of the work piece –Grinding disks are made from various types of abrasive materials. They are classified according to weight, size, arbor hole size (hole in the middle) and Rotations Per Minute (RPM) and material to be used on. This information can be found on the disk. Grinding disks are to be used for GRINDING only, DO NOT use to cut material. Use only the grinding face, not the back side of disk. –Cutting blades are classified according to size, bearing arbor hole size and thickness. This information is also found on the blades. Cutting blades are used for CUTTING only. DO NOT grind with them. Use only the edge.

10 May 201010 Wheel Example Max RPM Size of Disk Type of Material can be used on Cutting Blade

11 May 201011 Wheel Mounting Safety Disconnect power source before adjusting, oiling or changing accessories Use only parts supplied or approved by the grinder's manufacturer –nuts, flanges, guards, blotters, etc. Ensure wheel maximum speed is higher than grinder maximum speed –the grinder motor should burn up rather than the wheel flying apart Inspect wheel or attachment for cracks or flaws Clean wheel and grinder Perform a “ring test” on wheels prior to mounting (not applicable to all type wheels or other attachments and accessories) –Gently tap a dry clean wheel with a light nonmetallic tool—perhaps screwdriver handle for light wheels or wooden mallet for heavier ones –The tap should produce a clear metallic “ping.” If the sound is more like a dull thud, the wheel is probably cracked and shouldn’t be used. Be sure the wheel fits freely on the spindle. –Check that the arbor hole is the proper size for the grinder to be used The spindle nut must be tightened enough to hold the wheel in place, without distorting the flange –some manufactures require wrenches for tightening the wheel Ensure guard is replaced in the appropriate position After mounting wheel or brush and replacing the guard, stand to the side and allow a one minute run-up at no load to test integrity and balance of the wheel

12 May 201012 Other Accessories or Attachments Do not use unless: –The manufacturer recommends or approves its use on the product –The accessory limitations and specifications match those of the grinder speed, size, mounting and guarding requirements, etc. –The use of the accessory does not require the removal of or defeating of any guards, barriers or other safety-related devices unless they are replaced by other appropriate guards or protective devices. Follow manufacturer’s instructions for mounting approved accessories or attachments. Typical Wire Buffing Wheel Cup Stone Typical Wire Cup

13 May 201013 Guard Mounting Safety Grinders come equipped with a wheel guard that must remain in place at all times to protect the operator from –flying sparks and material –the blade itself Never operate without its guard in the proper place Use a guard supplied or approved by the tool manufacturer Report any missing, broken, or disabled guards “ Proper” placement of tool guard may vary. Handles can be moved on some angle grinders (to allow for right or left handed operation). Unlike in the photo above, the guard must be between the handle and the wheel.

14 May 201014 Proper Handling of Grinders Always use two hands when using a portable grinder –To maintain control The high speeds of the wheel can cause the grinder to fly off the metal –To keep both hands away from the hazard of the high speed rotation if a hand or finger hits the moving wheel surface, injuries will result if grinding on small pieces, may need to secure the work in a vise … DO NOT HOLD IN YOUR HAND

15 May 201015 Repetitive Motion Precautions Use firm hand grip force for control but without excessive force Avoid anything that inhibits blood circulation. –squatting for extended periods –improperly fitted gloves –other restrictions to comfortable body mechanics Avoid continuous vibration exposure. Keep wrists as straight as possible –Avoid repeated bending of wrists and hands. After each period of extended operation, exercise to increase blood circulation –flex wrists –change body position Minimize extent of reaching –to maintain better control of the tool and better body position To prevent potential repetitive motion injuries consider the need to reposition the work piece or your body rotate job duties change work pace

16 May 201016 Proper Grinder PPE Goggles or safety glasses with side shields AND a full face shield –to prevent chips or particles from getting into your eyes particles WILL fly in any grinding operation take appropriate precautions when removing goggles or safety glasses to ensure particles don’t fly into your eye even AFTER the grinding operation is done Leather Gloves –to protect your hands from flying particles and sharp edges created during the grinding operation, as well as the edge of the wheel itself Hearing protection Proper attire –don’t wear anything loose that could get caught in the rotation secure scarves, ties, loose hair, and dangling jewelry –if you’re wearing a long-sleeved shirt, button it at the wrist Consider the possible need for respiratory protection. –may be required for some grinding operation, depending upon the material of construction of the work piece being ground Local variations to PPE will be managed at a site level Be sure to maintain use of PPE for as long as hazard remains !!!

17 May 201017 Proper Use of Grinders Unless otherwise designed, grind on the face of the wheel - serious injury or damage could occur if the side of the wheel is used –use disc wheels for side-grinding –light side-grinding is permissible on cup or saucer wheels

18 May 201018 Critical Safe Behaviors for all Powered Tools Know and Follow all Manufacturer’s Instructions Use tool only for its intended purpose Maintain tools in proper condition –sharp & clean, lubricated –all guards in place –ensure any repairs performed by qualified persons Do not alter tools –to force pieces that don’t fit –or otherwise use the tool for an unintended purpose Perform a prior to use inspection of the tool Protect against electrical shock –use appropriate grounding ground plug in place, GFCI as appropriate –inspect cords & connections don’t abuse cords, keep away from heat, oil & sharp edges, inspect for frays, cuts, etc.

19 May 201019 Critical Safe Behaviors for all Powered Tools, continued Ensure all guards, grips, handles, etc. are in place Prevent unintentional starting of the tool –don’t carry powered tools plugged in with finger on switch –turn switch to off position when not in use Never carry a tool by the cord or hose. Never yank the cord or the hose to disconnect cord All portable electric tools that are damaged shall be removed from use and tagged "Do Not Use.“ Protect others in work area –don’t allow cords to become trip hazards –minimize number of employees in hazard zone –ensure all in hazardous areas are using appropriate PPE –consider work in adjacent or below areas

20 May 201020 Additional Grinder Specific Critical Behaviors Adjust handle and disk guard. The handle on an angle grinder can be mounted for either right or left handed users. –All angle grinders must be equipped with a handle. ANY exceptions must have written approval from Leadership prior to use. Allow grinder to come to full speed before contacting work surface Remove material or debris that might be ignited by sparks –Keep a properly charged fire extinguisher available Do not grind non-ferrous materials. Maintain steady pressure on the work piece –sudden “bumping”, pounding or impact could damage the wheel Do not apply excessive pressure to the wheel or disc so that the motor slows noticeably of the work gets hot –could stress the wheel, overheat the work piece and reduce your control

21 May 201021 Additional Grinder Specific Critical Behaviors Avoid letting the wheel rest on one spot for too long. –could cause the work to burn or the wheel to crack and explode. Keep good footing and maintain good balance Never attempt to grind in an awkward position. –A portable grinder can kick and glance off the work if not properly controlled Allow grinder to come to complete stop before removing PPE or setting tool down Do not touch the ground portion of the work piece until you are sure it is cool. Do not use liquid coolants with portable grinders. It could cause the metal to shatter. Make sure that the grinder is placed in a resting position that assures it can not be accidentally turned on

22 May 201022 Portable Grinder Safety Checklist Attached is a link to a Portable Grinder Quick Reference Card that can be used as a reminder of the critical behaviors associated with portable grinders for those persons –performing work using a portable grinder –observing those performing work using a portable grinder Grinder Use Checklist

23 Nov 2005 Bench Grinder

24 Nov 2005 The graphic below is courtesy of the Safety, Health, Environmental Technology Division of Georgia Tech Research Institute, Tech Guide No. 2, Published 1988. (Other local safety designations may apply instead of Z-87)

25 Nov 2005 If you damage a wheel or accessory during your work stop and replace the wheel or accessory - Do not leave damaged accessories for the next person to use Make sure that you unplug power from the grinder prior to performing any work to the grinder. Make sure that the bench grinder is located on a sturdy and stable bench or pedestal specifically made to support the bench grinder. Bench Grinder

26 Nov 2005 Using Bench Grinder –Turn on grinder and let the grinding wheels reach full speed prior to starting work on the material. –Apply pressure to the wheel slowly and square with the wheel. –When complete, turn off the grinder and make sure it comes to a complete stop before leaving the area. –If the items that are to be worked on are very small then the proper holding tools must be used to grip the work for grinding to secure from unexpected movement. Bench Grinder

27 May 201027 Conclusion Grinders are dangerous tools that can cause severe injuries or even death. safestGrinders should be chosen for the reason of performing the job in the safest manner first and saving time last. Use other tools when the associated inherent hazards are less severe. This Training is intended to increase your awareness of the dangers associated with the use of grinders. We are counting on you to use them safely in our facilities!

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