Welcome to the Inaugural Grain Handling Safety Stand Down Engulfment Education and Prevention Seminar

Size: px

Start display at page:

Download "Welcome to the Inaugural Grain Handling Safety Stand Down Engulfment Education and Prevention Seminar"

Jemimah Griffith
6 years ago
Views:

1 Welcome to the Inaugural Grain Handling Safety Stand Down Engulfment Education and Prevention Seminar

2 THANK YOU SPONSORS!! 2

3 Topics for Discussion Grain Engulfment History/Background. Types of engulfment and root causes. Engulfment Prevention Methods/Best Practices. Removal of grain from bins. Methods for keeping employees out of bins. Management Practices, Policies and Procedures. Bin Entry Procedures/Permits

4 Purdue University s Work Started collecting data in Initially focused on grain entrapments. Expanded focus to all confined spaces in All confined space incidents collected are entered in the Purdue University s Agricultural Confined Space Incident Database (PACSID). Summaries on incidents have been published annually for the last decade.

5 Grain Entrapments 2006 to 2016

6 All Agricultural Confined Space Incidents for 2016

7 Where do Grain Engulfment Incidents Occur? Grain Bin Silo Hopper bottom feed bin Grain Trailers Gravity Boxes/Wagons

8 Three Young Sisters Suffocate After Being Buried Under Grain at Family Farm While a truck was being unloaded they somehow fell into the canola seed. Two girls died at the scene as responders attempted to resuscitate them for over two hours. Third sister was airlifted to hospital in critical condition where she died the following day.

Purdue Engulfment Study 1964-2014 Children and youth account for

9 Purdue Engulfment Study Children and youth account for approximately 20% of all documented cases, most resulting in fatalities.

10 Other Findings Historically, 70% of the documented entrapments have occurred on exempt farms, while 30% occurred at non-exempt commercial facilities. There is a direct relationship between out-ofcondition grain and a greater probability of entrapment.

11 Contributing Engulfment Factors Increase volume/production of grain and feed being handled. Larger capacity storage facilities. Larger capacity handling equipment. Increase in the volume of exempt, on-farm storage. Longer term storage.

12 Contributing Engulfment Factors Out-of-condition grain/feed. Workers entering storage spaces alone. Farmers storing wetter corn to reduce energy costs. Changing workforce at commercial facilities lack agriculture background. Expanded use of grain for energy production.

13 How Does Engulfment Happen?

14 Flowing Grain Moving/flowing grain acts like quicksand Buries the worker in seconds. From time auger starts, you have 2-3 seconds to react. In 4-5 seconds you are trapped! In 22 seconds you are completely buried!

15 Bridged or Crusted Grain Bridging - Grain forms crust over top layers and creates an empty space beneath. Bridge can collapse when a worker walks on it and bury them.

16 Avalanching Grain A grain pile can avalanche unexpectedly on its own or when the worker attempts to dislodge it.

17 Engulfment/Entrapment Grain engulfment exposes workers to suffocation hazards. Leading cause of fatalities. Suffocation can occur from: Breathing in grain which blocks the respiratory system. Hazardous atmospheres.

18 Engulfment/Entrapment Grain engulfment also exposes workers to crushing or strangulation hazards due to the extreme weight or force being exerted on the body by the grain. This can cause Inability to breathe over time Irreparable damage to internal organs Buildup of toxins in the body

19 Force Required to Extract a Victim From Grain The effort required to pull someone from grain is a major hindrance to a quick rescue Do not use mechanical devices to remove a victim from grain

20 Engulfment Survival Rate

21 Reasons for Entry in Bins Containing Grain What are some of the reasons that cause you to enter into a grain bin? Plugged Sump Grain unloading problems (walking the grain) Installing Bin Sweeps Digging out Bin Sweeps Bin Inventory

22 ROOT CAUSE OF ENGULFMENTS? Employees are working in bins with TOO MUCH GRAIN!!!

23 Engulfment Prevention Methods What can be done to correct this? Get as much grain out of the bin as possible before employees enter to perform work. Keep employees out of bins as much as possible. How do we know when we ve removed enough grain from a bin to eliminate an engulfment hazard?

24 Angle of Repose There are documented angle of repose figures for all varieties of flowable solids including grain. The angle of repose is based on the fact that when a particular substance reaches it angle of repose the material will no longer flow naturally as long as it is not disturbed by any outside factors.

25 Angle of Repose Different grains have different angles of repose. Corn 21 to 23 degrees Wheat 25 to 27 degrees Soybeans 25 to 27 degrees Oats 28 degrees Barley 28 degrees

26 Angle of Repose Much of the grain industry is of the opinion that once the grain has stopped flowing, it has reached it s angle of repose and it is safe to enter. How do you know if the grain has reached its angle of repose?

27 Angle of Repose Many say they can tell just by looking. This is not a very safe or accurate method. If the grain is above or greater than its normal angle of repose there is generally a reason why and going into a bin under this condition exposes a person to an engulfment hazard.

28 Angle of Repose There are laser angle measuring instruments and phone apps available that can be used to measure the angle however, this requires a person to enter the bin and be exposed to a potential engulfment.

29 Angle of Repose Instruments such as this one shoot out a laser beam and locks in the angle. What some are doing is once the bin is empty, going to the center of the bin and measuring the angles of the different grains stored in the bin.

30 Angle of Repose Then different colored rings are painted around the inside walls of the bin. Each color denotes a different grain. Once the grain has been pulled down and the color is visible then the angle of repose can be verified by simply looking. Once the grain has reached its angle of repose the engulfment hazard has been eliminated.

31 Angle of Repose There are also charts that have been developed based on bin diameter to help assist with determining the angle of repose without the need to enter the bin. Using the chart you can determine how high the grain should be at the bin sidewall at its normal angle of repose.

34 OATS, BARLEY

35 Size and Number of Bin Sumps Many older bins have small sumps (12 x12 ). Many only have sumps on one side or half the bin diameter. These bins typically have a significant amount of grain left inside when pulled down.

36 Size and Number of Bin Sumps Newer bins now have: Sumps that go completely across the full diameter of the bin. Increased number of sumps on each side. Increased size of sump (up to 2X larger)

37 Size and Number of Bin Sumps Companies that are serious about reducing engulfment hazards are: Identifying existing bins where sumps can be added across the full diameter of bin. Putting in the largest available sumps in new bins. Increasing both the number and size of sumps in existing bins.

38 Size and Number of Bin Sumps Modifying and adding sumps will assist in removing as much grain as possible which in turn minimizes the engulfment hazard.

39 Running Bin Fans Run all bin fans while unloading grain from bin. Air movement through the grain along with the fan vibrations has been found to remove more grain from the bin than if the fans are not running. Several companies have incorporated this practice into their grain unloading procedures.

40 Getting Grain Out of Bins Before employees enter a bin you want to be sure that you have removed as much grain as possible. The angle of repose is at least equal to or less than the documented angle for the grain. These measures will help to minimize the engulfment hazard.

41 Keeping Employees Out of Bins Plugged Center Sumps Sending employees in a bin to clear a plugged center sump is a common practice and one of the leading causes of engulfment fatalities because once the plug is cleared the grain will immediately begin to flow and engulf the person.

42 Keeping Employees Out of Bins Plugged Center Sumps One method that has been found to be effective in clearing plugged center sumps is the installation of rods inside of a pipe with finger-like projections on the end.

43 Fingers can rotate up and down to break up plug. Rods move front and back within pipes. Since this installation, the company has not had to send anyone inside a bin to clear a plugged sump. Very easy and economical to install.

44 Rods are operated by employees from outside the bin and the fingers are positioned the same as those inside the bin.

Keeping Employees Out of Bins Plugged Center Sumps For bins with tunnels employees are oftentimes able to access the center sump discharge chute.

45 Keeping Employees Out of Bins Plugged Center Sumps For bins with tunnels employees are oftentimes able to access the center sump discharge chute. The access panel can be removed and rods used to dislodge or clear the plug from underneath. Companies have found this to be very effective in clearing out the sump. Access panel.

46 Keeping Employees Out of Bins Bridged, Cliffed, Caked or Towers All of the above conditions present serious engulfment hazards to employees when they enter the bin. These hazardous conditions are being addressed by companies as follows: This tower of grain is 65 tall.

47 Keeping Employees Out of Bins Bridged, Cliffed, Caked or Towers Contract Out the Work Utilize contractors who specialize in removing these types of grain hazards. Benefits include: Eliminates stranded investment expense in equipment and training costs. Contract workers are experienced in operating this equipment and are efficient with its use.

48 Mole Master and Pneumat Services

49 Keeping Employees Out of Bins Bridged, Cliffed, Caked or Towers Use of Grain Vacuums and Portable Augers Companies that are serious about keeping employees out of bins will use either of these options to deal with these grain issues. Both options will likely require that the bin be cut open. A portable auger can be inserted in the opening to both break up and unload the grain from the bin.

50 Keeping Employees Out of Bins Bridged, Cliffed, Caked or Towers Use of Grain Vacuums and Portable Augers Grain vacuums can accomplish the same end result. Depending upon conditions you may have to make several cuts or openings in the bin to break up and remove the grain.

51 Keeping Employees Out of Bins Bridged, Cliffed, Caked or Towers Use of Grain Vacuums and Portable Augers

52 Keeping Employees Out of Bins Zero Entry Sweep Auger Systems Another reason employees enter a bin is to set up or dig out sweep augers. Zero entry sweep augers are available by many manufacturers. These augers are powerful enough to start up and dig out of the grain without employees having to enter the bin at all.

53 Prevention Methods Production Management Practices Grain properly dried when harvested. Track bin temperatures through use of temperature cables so bin fans can be operated as needed to keep grain in the best condition possible. Be diligent in maintaining bins to prevent leaking.

54 Prevention Methods No Top Entry Eliminate top entries into bins if at all possible. Some companies are locking all top bin hatches with the Facility Manager being the only person with the key. Side entries are oftentimes safer but not always.

55 Prevention Methods No Top Entry OSHA does allow top entry from above the grain but requires the use of a safety harness and lifeline or a boatswain chair. BEWARE!! This is nearly impossible to accomplish.

56 Prevention Methods No Top Entry Most roof designs for steel bins do not allow for an adequate anchorage point for fall protection systems or the use of a boatswain chair.

57 Prevention Methods No Top Entry The anchor point must be directly overhead at all times which doesn t allow the person much freedom of movement. Some fall protection devices such as retractable lifelines will not work. The one benefit to wearing a harness and lifeline is if you do become engulfed the rescuers can find you easier by following the lifeline.

58 Illustration of successful rescue of worker during "bridging" condition. DO NOT ATTEMPT THIS!! IT WON T WORK!! The person on the inside of the bin is secured to the outside of the bin. The person on the roof can pass instructions and assist in lifting. The person on the ground can go for help or assist in pulling.

59 Prevention Methods Production Management Practices Anticipate that you will have problems ahead of time. Have a plan in place. Have access to the necessary equipment. Train employees ahead of time so adequately prepared.

60 Prevention Methods - Bin Entry Program Develop a company and/or farm Bin Entry Program. Permit or safety checklist Lockout/Tagout Atmosphere Testing Prohibit Top Entry Availability of rescue equipment Alternatives

61 Prevention Methods - Bin Entry Permit Required in commercial grain industry. Issued by the employer OR authorized person. Authorized person ensures permit requirements met. Best Practice (Farmers included) always fill out permit or checklist.

62 Bin Entry Permit Lockout/Tagout Lockout ALL energy sources. ALL conveying equipment. Only authorized/trained persons. Protects from unexpected start-up. Prevents dangerous flowing grain. Lockout MUST be done prior to entry!

63 Bin Entry Permit Lockout/Tagout Failure to lockout is one of the leading causes of engulfment!! Best practice for EVERYONE!

64 Bin Entry Permit Atmospheric Testing The atmosphere (air) inside bins can be very dangerous, even fatal. Air must be tested for: Oxygen content. No less than 19.5% No greater than 24.5 % Toxic Gases Hydrogen Sulfide (H2S) <10 ppm Carbon Monoxide (CO) <50 ppm Carbon Dioxide (CO2) <5000 ppm

65 Bin Entry Permit Atmospheric Testing Combustible Gases and Vapors Less than 10% of the lower explosive limit (LEL) Requires the use of a multi-gas monitor to check for these potential hazards. Cannot detect these using our own sense of smell. Hazardous atmospheres generally result in multiple fatalities.

66 Bin Entry Permit NEVER EVER go in a bin ALONE! Always have a standby person stationed at the entry point at all times while persons are inside a bin. Standby person doesn t leave his post until everyone inside the bin has exited. Standby person must always have a cell phone or other means of communication (2-way radio) to call for help in an emergency.

67 Bin Entry Permit - Rescue Must have a rescue plan in place. Must also have rescue equipment available that is suitable for the bin, silo or tank. Grain Recue Tube

68 Bin Entry Permit A member of top management must visually verify that the grain does not pose an engulfment hazard, review the entry permit to ensure all precautions have been taken and sign the permit authorizing the entry.

71 It Costs too Much to Comply! Yes, zero entry sweeps, modifying bin sumps, purchasing or renting grain vacuums and using contractors can cost a lot of money. It can also cost a lot of money when OSHA issues PENALTIES for engulfment incidents.

72 It costs too much to comply! Unfortunately it s the family who pays the ultimate price when an engulfment results in a fatality.

73 In Summary Remove as much grain as possible before allowing entry. This can be accomplished by: Adding more sumps. Increasing the size of the sumps. Running bin fans while unloading grain.

74 In Summary Devise a method to accurately determine if the grain has reached its angle of repose. Try to keep employees out of bins as much as possible by: Finding ways to clear plug sumps from outside the bin. Using contractors for removing bridged, caked, cliffed or grain towers inside bins.

75 In Summary Using grain vacuums or portable augers to remove grain when engulfment hazards are present. Installation of zero entry sweep augers.

76 In Summary Implement the following management practices, policies and procedures to prevent engulfment: Properly dry grain and utilize state of the art methods for monitoring grain to keep it in good condition at all times. In bad harvest years anticipate unloading problems and develop a plan.

77 In Summary Prohibit top entries into bins. Develop a bin entry program and make sure all hazards are properly addressed on the entry permit including precautions taken to prevent engulfment. Require top management to perform a visual inspection and sign off on permit prior to entry.

78 Compliance Assistance Specialists Kelly Bubolz Leslie Ptak U. S. Dept. of Labor - OSHA U. S. Dept. of Labor - OSHA 1648 Tri Park Way 4802 E. Broadway Appleton, WI Madison, WI (920) (608) Mary Bauer Jim Lutz U. S. Dept. Of Labor - OSHA U. S. Dept. of Labor - OSHA 1310 W. Clairemont Ave 310 W. Wisconsin Ave Eau Claire, WI Milwaukee, WI (715) (414)

79 Wisconsin Agri-Business Association Contact Jim Nolte, WABA Safety Director with any questions or suggestions you may have regarding engulfment hazards or issues. Phone:

80 QUESTIONS??

Grain Elevator Safety

Grain Elevator Safety Brad Freeman, CIH, CSP Gary Hulbert, CHMM, CSP Grain Elevator Overview Types and components of grain elevators OSHA standards Hazards associated with grain handling facilities: Engulfment