Machine Safeguarding 1000 Ton Transfer Press Risk Assessment

1. 2019-01-21
1
2
3
4
5
6
7
8
9
10
11
12
13
A B C D E F G H I J
MACHINE SAFEGUARDING RISK ASSESSMENT
1000 TON TRANSFER PRESS
Julian Kalac
Press/Machine: Date Assessment
New or Modified Review Date
Description Job Title:
COMPLIANCE
OHSA 851
SECTION
Operator or third accidently walkback,
fall back or slip backwards into
moving LIINEAR carriage
CRITICAL INJURY- SEVERE HEAD
TRAUMA 24, 25, 28 4 4 16
Installation – Not in compliance: Linear carrier stopping time =600ms,
requires Min.distance 31" CURRENT DISTANCE = 20" (320ms)--LINEAR NOT
ABLE TO STOP IN TIME BEFORE IMPACT--> OPTIONS TO REDUCE RISK : 1-
If light curtain cannot be extended further then reduce LINEAR servo stop
time to 300ms (minor PLC program change required), (LINEAR ABLE TO
STOP AT 140ms) OR OPTION 2 limit the head stroke by 5" and reduce the
brake monitor set trip time to 400ms. At 400ms Ds = 25inches
4 1 4
May 17 2018
May 22 2018
Safety Engineer
Name of person conducting Risk Assessment
PRESS 23 WITH SERVO TRANSFER
MODIFIED WITH IN PRESS SERVO DRIVEN TRANSFER
LINEAR TRANSFER AUTOMATION
Probabilit
y
Task
Hazard --Linear System or
Press
Initial risk
Risk Reduction Measures
Final risk
Severity Probability RPN
RPN =
PXS
Severity
Person moving at 1.6 meters/second will pass thru 20" light curtain in 312 ms, Linear stopping time = 500ms, Time to critical injury= 288ms
Control Measures
1. Hazard elimination
2. Substitution
3. Engineering controls
4. Administrative controls
5. PPE
20 – High
16 – High
12 – High
8 – High
4 – Low
4
Probability (P) Severity (S) Calculation of Risk (R) Action Level
1 2 3 5
20 - High
3 3 – Low 6 - Medium 9 - High 15 – High
2 2 – Low 4 - Low 6 - Medium 10 – High
Severity
5 >75%
4 50 - 75%
3 25- 50%
2 1- 25%
1 < 1%
Probability
5 5 – High 10 – High 15 – High 25 - High LOW – no action required
MED – justify /review for each event day
HIGH –immediate action/ further controls
needed
4 4 – Low 8 – High 12 – High
1 1 – Low 2 – Low 3 – Low 5 – High
1-First Aid Abrasion, Minor Cut,
2-Medical (Entanglement, Cut),
3-Serious (Impact -Broken Bone,),
4-Critical (Guard-Amputation)
5-Death/Fatality-LOTO

2. 2019-01-21
14
15
16
17
18
19
20
21
A B C D E F G H I J
2 OR MORE OPERATORS ,
ACCIDENTAL RESET RESTART ,
OPERATORS CANNOT SEE OTHER
SIDE
CRITICAL INJURY, DEATH 24, 25, 28 4 4 16
HORIZONTAL LIGHT CURTAIN INSIDE DANGER ZONE CONTINUOUS
DETECTION DUAL CHANNEL INTERLOCKED AND MANUAL RESET TIED TO
SAFETY CIRCUIT LMC inputs
4 1 4
2 OR MORE OPERATORS ,
OPERAT FORGETS TO LOCKOUT,
NO TAGS USED
CRITICAL INJURY, DEATH 24, 25, 28 4 4 16
LOCKOUT TAG OUT PROCEDURE, LOCK /TAG MUST BE PLACED ON DIE
HOLDING BLOCK PLUG WHEN INSIDE DIE AREA
4 1 4
NOT COMPLIANT WITH OHSA COMPLIANCE 27, CSA Z432 N/A N/A N/A
It is suggested that the existing pushbuttons for “immediate stop” be replaced with
self-latching button type that requires a deliberate pull-to-release or twist-to-release
action, in order to provide further protection against accidental restar
N/A N/A N/A
PRESS ESTOP NOT HARD
WIRED , does not stop
motor/flywheel, does not override
faults, does not prevent restarting
and does not comply with
mandatory OHSA and CSA
requirements
IF BRAKES FAIL OR PRESS
MOTOR OR LINEAR
CONTROLS FAIL TO STOP --
CRUSHED, AMPUTATION ,
ELECTRICAL SHOCK
27 3 3 12
STRONGLY RECOMMEND HARD WIRING E-STOP TO MAIN MOTOR PRESS .
ENSURE FLYWHEEL IS DISENGAGED FROM MOTOR, constituting a non-
compliance as per section 5 AND 8 OF CS Z432-04
3 1 3
Estops DO NOT PREVENT
RESTARTING EQUIPMENT, NO
RELEASE OF ENERGY
AMPUTATION CRUSHING--IF
STOP CYCLE FAILS TO STOP
27 4 2 8
It is recommended that the cycle stop buttons be replaced with yellow buttons to not
be mistaken for emergency
4 1 4
E-STOP SOFT STOP
CRUSHED, AMPUTATION ,
ELECTRICAL SHOCK
27,74,75, 4 2 8
STRONGLY RECOMMEND HARD WIRING E-STOP TO OVERRIDE ALL OTHER
M,ACHINE CONTROLS AS REQUIRED BY CSA Z432 -04 SECTION 7.17.1.1
4 1 4
LINEAR TRANSFER 480 V NOT
INTERLOCKED WITH DIE RAM
BLOCKS DURING PRESS LOCK OUT--
LIVE WIRE
ARC FLASH , ELECTRIC SHOCK
DEATH
42, 43, 75 AND
76
5 3 15
MUST LOCK OUT HIGH VOLTAGE POWER WHEN PRESS LOCKED OUT.
DEVELOP SAFE WORK PROCEDURE FOR PROPER POWER DOWN 480V
5 2 10
NO LOCK OUT PROCEDURE FROM
LINEAR ON PRESS 39 OR 23 FROM
LINEAR
ARC FLASH , ELECTRIC SHOCK
DEATH
42, 43, 75 AND
76
5 3 15
NEED LOCK OUT POINTS IDENTIFIED ON LINEAR AND RECOVERY FROM
EMERGENCY STOP PROCEDURE
5 1 5

3. 2019-01-21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
A B C D E F G H I J
RUNAWAY SERVO MOTOR
LINEAR TRANSFER --
OVERRUNING
IMPACT UNCONTROLLED
MOTION
75 76 3 3 9
safe torque off function AND SAFE BRAKE CONTROL MUST BE PROGRAMMED
INTO CODE
3 1 3
Starting and operation of
equipment in any mode
Entanglement and pinch point
hazards at flywheel, motor,
drive, and crankshaft
42 REG 851 3 3 9
42. (1) The power supply to electrical installations, equipment or conductors shall
be disconnected, locked out of service and tagged before any work is done, and
while it is being done
3 1 3
ALL TASKS
Slip/trip/fall from oily surface
near linear robot
25
(b) be located within easy reach of the operator. R.R.O. 1990, Reg. 851, s. 27.
Current Press Controls are control reliable, light curtain fault prevents press
from restarting . Linear to verify control reliable
Stopping time of Linear needed for light curtain distance
Improper shut down of electrical
power
Electric shock , Arc flash 42 , 75 76 3 2 9
Need to develop proper LOTO , identify authorized maintenance and train them on
proper LOTO
3 1 3
Linear Lock-out procedure Interlocked access doors into feed area
Interlocked light curtain into press tooling area
Deliberate restart from outside safeguarded space
Improper shut down of electrical
power
ELECTRIC SHOCK ARC
FLASH HIGH VOLTAGE
25, 26, 75 &
76, 42
4 3 12
Need to develop proper LOTO , identify authorized maintenance and train them on
proper LOTO
4 1 3
Crushed Arm/hand in die area 25 Light Curtain with Fixed side guard or double sided liught curtain
Release of stored air energy in
jammed pneumatic mechanism
75,76 Linear to ensure Electronic air dump when emergency stop actuated.
3
1 11 4 4
Slip Resistant PPE, Administrative Controls: Spill clean kits, SOP oil spills must be
cleaned up immediately to porevent injury
1
25, 26, 75 & 76
75,76
1 4
Maintenance/Tool Maker entering
inside die
Crushed struck or pinched by
any moving parts
4 3 12 4 1 2
Linear and Die Clear jam-up 4 4 16 4
Protection of personnel entering the equipment to perform maintenance FULL LOCK OUT TAG OUT REQURIED FOR ANY MAINTENANCE WORK
1 3
Clearing jam-ups, minor die
adjustment
Struck, pinned, or pinched by
Linear Transfer tooling during
normal operation
3 2 6

4. 2019-01-21
37
38
39
40
41
42
43
44
45
46
4748
49
50
51
52
53
54
A B C D E F G H I J
Maintenance Clearing jam-up
Gravity fall of pneumatic tooling
or other components
75,76 1 1 1
Stroke and weight of tooling and workpieces is not considered to present significant
risk of injury.
Crushing hazard in die area 75,76
– powered motion – excluding
“Inch” mode
75,76
Scrap removal Maintenance Crushing hazard in die area 75,76
Full LOTO main motor disconnect Automatic brake/restraint; counterbalance
system; ram blocking
Linear Tool changing and set-up
Threading feed material Clearing
jam-up
– Falling by gravity when not
powered
75,76
Residual risk is associated with ram blocking because there is no technically
feasible method of enforcing its use. Training in machine operating procedures,
machine entry procedures, lock- out procedures, and warning signs are feasible
countermeasures.
Maintenance Linear Tooling 75,76
Tool changing and set-up 75,76
Overload protection; arrangement of fixtures to accept only correct parts and only
correctly oriented parts
27 Personal protective equipment must be used per Clause 14 of CSA Z142-10.
Tooling must be designed to contain workpieces to the extent feasible. Since this
machine can be used with different tooling, the on-going responsibility for
appropriate tooling design to eliminate this hazard must lie with the tooling designer.
26
Sustained-contact manual control for “jog” of feeder in manual mode. The sustained-
contact manual controls comply with CSA Z432-16 clause 7.21.
Guides for the material are provided.
25, 26, 75 &
76, 42
Manual re-start required at end of roll from adjacent operator station with clear view
of hazard area.
Personal protective equipment must be used per Clause 14 of CSA Z142-10.
Fixed guarding.
25, 26, 75 &
76, 42
Parts to be dropped into bin; further handling is outside the scope of this report.
no action
3 1 3
3 1 3
Removal of finished parts
Pinch points at parts take- away
conveyor
3 3 9
All operating conditions in which
strip is being used – when running-
out the tail end of the coil
End-of-coil “whipping” hazard 3 3 9
1 3
1 2
Threading roll-fed material
through die at start of roll
Pinch point between leading
edge of feed material and die
components; pinch points of die
associated with necessary
motions during
3 2 6 3
Loading or unloading parts
improperly (double fed, improper
parts loaded, proper parts loaded
incorrectly)
Tooling hazards – potential for
ejecting workpieces or tooling in
a hazardous manner
2 2 4 2
4
Crushing hazards associated
with heavy tooling components
or
4 2 8
Already in place Lift assist devices or Provide suitable means of lifting, and
adequate clearance within and around the equipment
4 1
5
4 1 4
5 2 10 5 1
Scrap removal Maintenance
Clearing jam-up
4 4 16
Lock out tag out procedure needs to be developed and ensure that the 480v
disconnect is locked out and intelock ram blocks used to prevent stored energy
from releasing. Full LOTO must be done during any maintenance