Transcript Portable Grinder Safety

Grinder Use Safety Training
Introduction
• Grinders are dangerous tools that can cause severe
injuries or even death.
• Grinders 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.
Nov 2005
Freeport Grinder Use Training
Requirements
• 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.
Nov 2005
Grinder Related Injuries
• 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.
May 2010
Grinders have
contributed to
fatalities!
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Most Recent Grinder Injuries
• 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.
Grinders have
contributed to
fatalities!
Freeport is taking measures to achieve the vision
of an injury-free workplace.
May 2010
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What are the Common Hazards
of Grinder Use?
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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
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Inhaling dust and fumes generated
Explosion or fire
– if sparks ignite flammable or combustible materials nearby or below grinding
operation
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Electric shock from frayed or defective power cord
Noise
Musculoskeletal disorders (MSDs) from
– repetitive use
– awkward body positions
May 2010
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Common Causes of Grinding
Incidents
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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
May 2010
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Critical Grinder Wheel Safety
Issues
• Some Grinding wheels can be surprisingly delicate. They can be
easily damaged if handled carelessly.
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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.
May 2010
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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.
May 2010
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Wheel Example
Cutting Blade
Max RPM
Size of Disk
Type of Material
can be used on
May 2010
10
Wheel Mounting Safety
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Disconnect power source before adjusting, oiling or changing accessories
Use only parts supplied or approved by the grinder's manufacturer
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Ensure wheel maximum speed is higher than grinder maximum speed
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May 2010
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)
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nuts, flanges, guards, blotters, etc.
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
11
Other Accessories or Attachments
•
Typical Wire
Buffing Wheel
Typical Wire Cup
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.
Cup Stone
May 2010
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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
May 2010
“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.
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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
May 2010
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Repetitive Motion Precautions
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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
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reposition the work piece or your body
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rotate job duties
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change work pace
May 2010
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Proper Grinder PPE
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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 !!!
May 2010
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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
May 2010
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Critical Safe Behaviors for all
Powered Tools
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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.
May 2010
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Critical Safe Behaviors for all
Powered Tools, continued
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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
May 2010
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Additional Grinder Specific
Critical Behaviors
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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
May 2010
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Additional Grinder Specific
Critical Behaviors
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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
May 2010
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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
May 2010
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Bench Grinder
Nov 2005
•
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)
Bench Grinder
• 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.
Nov 2005
Bench Grinder
• 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.
Nov 2005
Conclusion
• Grinders are dangerous tools that can cause severe
injuries or even death.
• Grinders 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!
May 2010
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