MID-ATLANTIC GEAPS JANUARY 2013 MEETING PRESENTED BY: Johnny Wheat. 4B Components Limited

Transcription

1 MID-ATLANTIC GEAPS JANUARY 2013 MEETING PRESENTED BY: Johnny Wheat 4B Components Limited

2 4B Worldwide B UK B USA B France B Germany B Asia B Africa B Australia

3 4B U.S.A. NEW 53,000 Sq. Ft. Facility Morton, IL

4 U.K. Factory Aerial view of the factory in Leeds, U.K.

5 Electronic Products

6 Material Handling Products

7 YOUR PROBLEM: Grain dust is explosive YOUR SOLUTION: Remove one of the elements from the dust explosion pentagon Ignition Source (Heat) Dispersion of Dust Particles Confinement of the Dust Cloud Combustible Dust (Fuel) Oxygen in Air (Oxidizer) Dust Explosion Pentagon

8 Common Ignition Sources: 1. Belt Slip 2. Belt Misalignment 3. Hot Bearings

9 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

10 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 M800 Elite Speed Switch Sensor

11 Standard (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.

12 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 Sensor machine Touchswitch Sensor

13 Standards (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.

14 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 ADB Bearing Temperature Sensor Sensor

15 Standard (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.

16 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

17 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

18 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

19 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

20 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!!!

21 Standard App A (See Actual Standard For Full Interpretation) 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

22 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

23 OSHA & NFPA STANDARDS (See Actual Standard For Full Interpretation: OSHA , NFPA 61, NFPA 654) Hazard Belt Slip Belt Misalignment Bearing Failure Pulley Misalignment Plugged Spout Requirement Motion detection device to provide a shutdown and alarm at 20% reduction in normal belt speed. Also shutdown of feeding equipment. Belt alignment monitoring devices at head and tail pulleys, which initiate an alarm. Bearing temperature or bearing vibration monitors which activate and alarm. Head pulley alignment monitors which activate an alarm. Sensors which provide a shutdown and alarm when there is a plug condition. Also shutdown of feeding equipment.

24 NFPA STANDARDS 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)

25 TYPICAL SENSORS FOR HAZARD MONITORING Speed & Belt Slippage Belt Misalignment Bearing Temperature

26 TYPICAL CONTROLS FOR HAZARD MONITORING Watchdog Elite Single Machine Hazard Monitor PLC T500 Hotbus Multi Machine Hazard Monitor

27 TYPICAL TEST EQUIPMENT FOR HAZARD MONITORING SYSTEMS Tech Team On-Site Testing & Commissioning Services UNDERSPEED TESTING BEARING TEMPERATURE TESTING SERVICES

28 THE FUTURE IS HERE... CLOUD BASED HAZARD MONITORING Real Time System Information From Any Web Enabled Device Password Protected Network Send Alert Notifications Customizable System and Sensor Naming

29 QUESTIONS?