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Hazard Monitors for Grain Elevators
1.
Johnny Wheat Brian Knapp 4B Components Limited PRESENTED
BY: Copyright 2012 © 4B Components Ltd. All Rights Reserved
2.
Combustible Dust (Fuel) Dispersion of Dust
Particles Ignition Source (Heat) Confinement of the Dust Cloud Oxygen in Air (Oxidizer) YOUR PROBLEM: Grain dust is explosive YOUR SOLUTION: Remove one of the elements from the dust explosion pentagon Copyright 2012 © 4B Components Ltd. All Rights Reserved
3.
Common Ignition Sources: 1.
Belt Slip 2. Belt Misalignment 3. Hot Bearings Copyright 2012 © 4B Components Ltd. All Rights Reserved
4.
If you eliminate
these ignition sources then you not only considerably reduce your chance of having an explosion, but you also realize every day values of: 1. Improved Preventative Maintenance 2. Smoother Running Equipment 3. Longer Service Life for Equipment Copyright 2012 © 4B Components Ltd. All Rights Reserved
5.
YOUR PROBLEM: Belts
slipping on the head or drive pulley of a machine is an ignition source YOUR SOLUTION: Install a speed switch at the tail end of the bucket elevator or conveyor to warn when the belt starts to slip and automatically stop the machine Sensor M800 Elite Speed Switch Copyright 2012 © 4B Components Ltd. All Rights Reserved
6.
Standard 1910.272(q)(5) The employer
shall equip bucket elevators with a motion detection device which will shut-down the bucket elevator when the belt speed is reduced by no more than 20% of the normal operating speed. Copyright 2012 © 4B Components Ltd. All Rights Reserved
7.
YOUR PROBLEM: Belts
misaligning and rubbing against a machine’s casing is an ignition source YOUR SOLUTION: Install belt misalignment sensors at the drive and tail ends of the bucket elevator to warn when the belt starts to rub and automatically stop the machine Sensor Sensor Touchswitch Copyright 2012 © 4B Components Ltd. All Rights Reserved
8.
Standards 1910.272(q)(6)(i) &
(q)(6)(ii) Equip bucket elevators with a belt alignment monitoring device which will initiate an alarm to employees when the belt is not tracking properly. Copyright 2012 © 4B Components Ltd. All Rights Reserved
9.
YOUR PROBLEM: Bearings
overheating are ignition sources YOUR SOLUTION: Install bearing temperature sensors on all critical bearings such as the drive and tail bearings to warn when a bearing reaches a high temperature and automatically stop the machine Sensor Sensor ADB Bearing Temperature Sensor Copyright 2012 © 4B Components Ltd. All Rights Reserved
10.
Standard 1910.272(q)(4)(ii) Provide vibration
monitoring, temperature monitoring, or other means to monitor the condition of those bearings mounted inside or partially inside the leg casing. Copyright 2012 © 4B Components Ltd. All Rights Reserved
11.
YOUR PROBLEM: Electrical
equipment can itself, be an ignition source for a grain dust explosion YOUR SOLUTION: Only install equipment approved / listed and certified by an NRTL (Nationally Recognized Testing Laboratory) Class II Division 1 Group G - • For example, inside a bucket elevator or belt conveyor Class II Division 2 Group G - • For example, outside a bucket elevator or belt conveyor Copyright 2012 © 4B Components Ltd. All Rights Reserved
12.
YOUR PROBLEM: You
are not confident that your local electrical service supplier has the experience and knowledge required to professionally install a hazard monitoring system YOUR SOLUTION: 1. Send your electrician to the manufacturers facility for training on the equipment to be installed 2. Have the manufacturer install the system or recommend a suitable installer Copyright 2012 © 4B Components Ltd. All Rights Reserved
13.
YOUR PROBLEM: Operators
continue to operate equipment despite hazard monitoring systems indicating that there is a hazardous condition YOUR SOLUTION: 1. Educate operators on the hazards of grain dust explosions 2. Instruct operators of the severe penalties that will be enforced if they do not follow company policy 3. Automatically log all alarms and shutdowns so that operators understand that there is a permanent record and they are accountable Copyright 2012 © 4B Components Ltd. All Rights Reserved
14.
YOUR PROBLEM: Equipment
does not perform to your expectations YOUR SOLUTION: 1. Inspect the system and installation 2. Commission the system 3. Test the system, both initially and periodically 4. Train the operators and management on the capabilities, use, maintenance and testing of the system Copyright 2012 © 4B Components Ltd. All Rights Reserved
15.
YOUR PROBLEM: A
sensor or control is damaged and the only way to run equipment is by electrically bypassing the hazard monitoring system YOUR SOLUTION: DO NOT RUN IN BYPASS. Have spare sensors and components available for immediate replacement so that down time is reduced to a minimum ! ! ! WARNING ! ! ! Copyright 2012 © 4B Components Ltd. All Rights Reserved
16.
Standard 1910.272 App
A It is imperative that the prearranged schedule of maintenance be adhered to regardless of other facility constraints. The employer should give priority to the maintenance or repair work associated with safety control equipment… (See Actual Standard For Full Interpretation) Copyright 2012 © 4B Components Ltd. All Rights Reserved
17.
YOUR PROBLEM: 1.
OSHA has stepped up its facility inspection and audits in conjunction with their National Emphasis Program (NEP) on dust explosions 2. OSHA is finding twice as many violations in relation to the NEP inspections compared with all other types of facilities. One such violation is that bucket elevators and conveyors are not equipped with bearing temperature, belt alignment and underspeed detection monitors YOUR SOLUTION: 1. Understand the dangers of grain dust, and implement a program of compliance to not only OSHA regulations, but also NFPA and other standards 2. Install hazard monitors (as discussed earlier) to help eliminate ignition sources Copyright 2012 © 4B Components Ltd. All Rights Reserved
18.
OSHA & NFPA
STANDARDS (See Actual Standard For Full Interpretation: OSHA 1910-272, NFPA 61, NFPA 654) Hazard Requirement Belt Slip Motion detection device to provide a shutdown and alarm at 20% reduction in normal belt speed. Also shutdown of feeding equipment. Belt Misalignment Belt alignment monitoring devices at head and tail pulleys, which initiate an alarm. Bearing Failure Bearing temperature or bearing vibration monitors which activate and alarm. Pulley Misalignment Head pulley alignment monitors which activate an alarm. Plugged Spout Sensors which provide a shutdown and alarm when there is a plug condition. Also shutdown of feeding equipment. Copyright 2012 © 4B Components Ltd. All Rights Reserved
19.
o NFPA 61
Standard for agricultural and food processing industry (rev. 2008) o NFPA 68 explosion venting standard (rev. 2007) o NFPA 69 prevention standard (rev. 2008) o NFPA 70 NEC (rev. 2008) o NFPA 77 static electricity (rev. 2007) o NFPA 499 guide to combustible dust area classifications (rev. 2004) o NFPA 654 standard for general industry (rev. 2006) NFPA STANDARDS Copyright 2012 © 4B Components Ltd. All Rights Reserved
20.
TYPICAL SENSORS FOR
HAZARD MONITORING Speed & Belt Slippage Belt Misalignment Bearing Temperature Copyright 2012 © 4B Components Ltd. All Rights Reserved
21.
TYPICAL CONTROLS FOR
HAZARD MONITORING Watchdog™ Elite Single Machine Hazard Monitor PLC T500 Hotbus™ Multi Machine Hazard Monitor Copyright 2012 © 4B Components Ltd. All Rights Reserved
22.
QUESTIONS? Copyright 2012 ©
4B Components Ltd. All Rights Reserved
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