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Purdue University’s 2023 report on agricultural confined space-related injuries and fatalities reveals both alarming trends and areas of improvement within the industry. While there has been a notable decrease in the number of incidents compared to previous years, the statistics underscore the ongoing risks associated with confined spaces in agriculture.

Key Findings

• Overall Cases: A total of 55 cases were documented in 2022, which includes 29 fatal and 26 non-fatal incidents. This represents a significant 33.7% decrease from the 83 cases recorded in 2021.
• Grain Entrapments: The report documented 27 grain-related entrapments in 2022, showing a 35.7% decrease from the previous year. The remaining cases involved livestock waste handling, entanglements, and incidents related to grain dust explosions or fires.
• Multiple Victims: Three incidents involved multiple victims, highlighting the potential for widespread danger in confined spaces.
• Gender Representation: The report noted two female cases, including a dairy farm manure pit explosion and a fall from a grain elevator.
• Geographic Distribution: Illinois reported the highest number of confined space-related cases (12), followed by Iowa (5). Historical data indicates that states like Iowa, Indiana, and Minnesota continue to account for a large percentage of grain entrapment cases.
• Grain Dust Explosions: There were nine documented grain dust explosions at commercial facilities, resulting in 12 non-fatal injuries. Fortunately, no fatalities were reported in these incidents.
• Aging Workforce: The average age of victims continues to rise, reflecting the increasing age of farmers in the U.S. In 2022, victims over 60 years old made up 28.6% of the cases where age was known.

Trends and Insights

Since the 1970s, Purdue University’s Agricultural and Biological Engineering Department has diligently documented incidents involving grain storage and handling facilities. This effort expanded in 2013 to include a broader range of agricultural confined space incidents, resulting in a comprehensive database (PACSID) containing 2,378 cases as of the end of 2022.

Despite the positive trend of fewer incidents, the report emphasizes the persistent need for effective safety training and proactive measures to protect workers. The methodology for collecting this data remains consistent, and while the numbers show improvement, the report acknowledges that many incidents, particularly non-fatal cases, may go unreported.

The Cost of Agricultural Confined Space-Related Incidents is Increasing

The economic implications of agricultural confined space incidents have changed significantly over time. In the past, the costs associated with fatalities or injuries were often manageable, covered by family, insurance policies, or local community support. However, with stricter OSHA regulations and increased scrutiny on workplace safety, non-exempt employers now face substantial financial risks. Jurisdictions have highlighted that neglecting employee safety can lead to hefty legal settlements, often reaching $10-17 million in cases involving fatalities or serious injuries, dwarfing OSHA fines that typically range from $50,000 to $100,000.

Valuable Resources for Safety Training

To aid in addressing these challenges, the website http://www.agconfinedspaces.org/ has been developed with support from a U.S. Department of Labor Susan Harwood Grant. This platform provides resources for safety training in agricultural confined spaces, focusing on grain storage and handling hazards. It includes:

• Training materials and frequently asked questions.
• Historical summaries of injuries and fatalities.
• Educational resources aimed at young and beginning workers in the grain industry.

One highlighted program, “Against the Grain,” offers a comprehensive curriculum designed for youth and new employees at grain handling facilities. Since its launch, it has reached over 5,100 young individuals, demonstrating significant knowledge gains.

Additionally, training resources for emergency responders have been developed, with over 5,425 responders participating in these training sessions.

Conclusion

The findings from the 2023 report underscore the importance of focusing not only on reducing the number of incidents but also on strategically enhancing training for first responders. As the agricultural industry continues to evolve, so must our approaches to safety and emergency preparedness.

For a detailed look at the 2022 findings, methodology, and historical trends, please refer to the full report here.

During a recent safety inspection at a grain facility, one of our subject matter experts made it a point to engage with the facility manager and front line employees about their safety concerns. Typically, they expect to hear common issues like bin entry risks, worker fatigue, or the dangers of working on top of railcars. However, this time, the manager brought up an unexpected concern: multitasking.

This revelation was eye-opening. The manager expressed his discontent with employees splitting their attention between tasks, highlighting how it compromises their focus and safety. He emphasized the importance of assigning one task at a time, allowing employees to complete it fully before moving on to the next.

The Myth of Multitasking

Multitasking is often viewed as a desirable skill in today’s fast-paced work environment. Many individuals might find themselves checking emails, texting, or taking calls while attempting to focus on their primary task. However, studies indicate that multitasking is not only ineffective but can also be dangerous.

The human brain is not wired to handle multiple tasks simultaneously. Instead of multitasking, individuals are merely switching their attention between tasks. This constant switching can lead to decreased accuracy, impaired judgment, and increased reaction times. According to a study by the University of California, distractions account for 32% of worker accidents, underscoring the dangers of divided attention.

The Impact of Distraction

The consequences of distraction can be severe. The National Highway Traffic Safety Administration reports that approximately 100 people die daily in vehicle crashes, with the risk of accidents increasing by 17% when drivers use their cell phones. While this scenario differs from working in a grain facility, the risks of distraction and its potential to cause accidents are similar.

Shifting to Monotasking

To mitigate the risks associated with multitasking, it is advisable to adopt a monotasking approach. This shift can enhance focus and reduce distractions, ultimately leading to a safer work environment. Here are some effective strategies to implement monotasking in the workplace:

1. Prioritize Tasks: Begin by ranking tasks based on urgency and the focus required. Tackle the most critical and demanding tasks first thing in the day. Studies have shown that individuals who complete challenging tasks in the morning perform significantly better than those who do so later in the day.
2. Structure Breaks: Incorporate structured breaks into the workday. Research indicates that taking regular 15-minute breaks can dramatically increase productivity. Employees should be encouraged to socialize during these breaks, avoid cell phone usage, and get outside for fresh air. This practice not only revitalizes employees but also enhances their focus and problem-solving skills.
3. Educate Employees: Raise awareness among employees about the connection between distractions and workplace injuries. Emphasize the importance of monotasking and structured breaks to improve their focus and safety.

While eliminating multitasking may not always be feasible, fostering a work environment that promotes monotasking can lead to better productivity, higher quality work, and a safer atmosphere for all employees. Encouraging the team to focus on one task at a time can make a significant difference in their well-being and safety. Remember, sending employees home safely is the ultimate goal.

This blog drafted from an article by Joe Mlynek, published in July/August 2024 edition of Grain Journal Magazine.

Agriculture is one of the most dangerous industries in the world, with high rates of occupational injuries, illnesses, and fatalities. The U.S. Bureau of Labor Statistics (BLS) consistently reports that agriculture has the highest rates of injuries of any major industry sector in the United States. In 2021, agriculture saw 19.5 fatal injuries per 100,000 full-time equivalent (FTE) workers. Specific subsectors, such as beef cattle production, face even greater risks. Nearly 45% of feedlot injuries involve handling cattle, making safety a top priority in feed yard operations. To create a safer environment for both workers and livestock, here is a viable list of feedlot safety tips. We’ve linked courses pertaining to each topic below. Please click the underlined text to learn more or test drive a full course.

Low-Stress Cattle Handling

Cattle handling is a leading cause of injuries in feedlots. Understanding cattle behavior and implementing low-stress handling techniques are critical. By respecting the flight zone (cattle’s personal space) and using predictable movements, handlers can reduce stress and prevent dangerous situations. Building trust with cattle is essential to minimizing risks.

Horses

Horses are involved in approximately half of all cowboy incidents. Since horses present a variety of safety challenges it is critical to have thorough horse selection criteria before they are deployed, and that they are trained for the specific situations where they will be used. The Brandon Wenta Tragedy, Cowboy Safety: Horses and Pen Conditions and Cowboy Safety: Cattle Movement are courses we offer on this subject.

Proper Equipment Maintenance & Use

Maintaining equipment like tractors, skid steers, and feed trucks is vital for preventing accidents. Regular inspections and prompt repairs ensure machinery operates safely, reducing the risk of malfunctions that could lead to injuries.

Slip, Trip, and Fall Prevention

Feedlots present various slip, trip, and fall hazards. Slick pen conditions are common year-round, and weather is always a factor. Proper footwear is essential. Preventing falls from heights such as bins and legs requires extensive training and use of special equipment. Remembering the three-point contact rule (two hands and a foot or two feet and a hand) reduces the probability of slips and falls when climbing ladders and when entering / exiting equipment.

Safe Operation of Mobile Equipment

Training workers on the safe operation of mobile equipment, such as feed trucks, loaders, UTVs (utility task vehicles), and ATVs (all-terrain vehicles) is crucial. Emphasize the importance of wearing seat belts and staying alert in areas where livestock or other workers are present. If you use ATVs consider replacing them with UTVs since they are inherently safer.   

Lockout/Tagout

Lockout/Tagout (LOTO) procedures are essential for preventing accidental equipment start-ups that could lead to serious injuries or fatalities. Ensure all workers are trained on LOTO protocols, which involve isolating and securing machinery before maintenance or repair work is performed. Proper LOTO practices are critical for protecting workers from unexpected releases of hazardous energy.

Fire and Explosion Safety

Fire safety is critical in feedlots due to the potential for fires and dust explosions. Establishing no smoking areas and using explosion proof fixtures and wiring are critical prevention measures. Ensure that fire extinguishers are well maintained, conduct fire/explosion drills and have all workers practice the fire evacuation plan. Hot work, such as welding, cutting, or grinding poses significant fire and explosion risks. Always follow proper hot work safety procedures, including obtaining permits and ensuring fire watches are in place.

Bin and Confined Space Entry Safety

Grain bins and confined spaces such as boot pits pose significant risks including engulfment, falls, and hazardous atmospheres. Workers should never enter these areas until an entry permit is completed and safety measures are followed. Always use appropriate harnesses and lifelines and ensure that all equipment is locked out and tagged out before entry. Ventilation should be tested to confirm it is safe before entry, and workers must be trained on the risks and proper safety procedures associated with bin and confined spaces and falls from heights. Our course, It Was A Good Friday: Grain Entrapment and Engulfment provides an impactful look at the importance of this issue.

Hydration and Heat Stress Prevention

Working in hot conditions can lead to heat stress and dehydration. Provide shaded rest areas, ensure easy access to water, and educate workers on the signs of heat-related illnesses and the importance of staying hydrated.

Emergency Preparedness

Every feedlot should have a clear, well-communicated emergency response plan. This includes procedures for handling medical emergencies, fires, severe weather, and other potential hazards. Regularly review and practice these plans with all employees to ensure everyone knows their role in an emergency.

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Feedlot safety is multifaceted, requiring attention to a range of hazards from cattle handling to equipment maintenance and emergency preparedness. By implementing these safety tips, feed yards can significantly reduce the risk of injury and create a safer, more efficient working environment.

Remember, a commitment to safety is essential at all levels of the operation. Continuous training, vigilance, and proactive safety practices are the keys to protecting workers and livestock in this high-risk industry.

In the realm of agricultural safety, understanding environmental risks in confined spaces is crucial. These hazardous environments present unique risks that demand awareness and proper safety protocols.

Why Focus on Agricultural Confined Spaces?

Agricultural confined spaces are essential for storing and handling crops. They pose serious risks to those who work in and around them. From engulfment hazards to toxic gases, these environments require careful management and adherence to safety guidelines.

Joe Mlynek, a partner at Safety Made Simple, presented for the National Grain and Feed Association (NGFA) webinar series on June 18th, 2024. He discusses the hazardous environmental risks associated with agricultural confined spaces in this video link. His insights are invaluable for anyone involved in agricultural operations or safety management.

Resources

For more educational resources on grain safety and agricultural confined spaces, visit the National Grain and Feed Association‘s safety page at ngfa.org/safety. Safety Made Simple subscribers can register for the hazardous atmospheres in confined spaces course by clicking here. This session focuses on atmospheric hazards in confined spaces. By the end of this course, participants will be able to recognize the effects of oxygen deficiency on the body, identify common atmospheric hazards and their health effects, and apply safe practices for atmospheric testing and ventilation in confined spaces.

Together, with the NGFA, we prioritize safety in agricultural operations. Stay informed about the latest safety practices and resources to protect yourself and your team. Together, we can mitigate risks and create a safer working environment.

As summer heats up, so does the need for heightened safety awareness in maritime facilities like shipping and barge loading terminals. While the water may look inviting, it poses unique risks to workers, making it essential to have proper protocols and equipment in place to ensure their safety. Here’s what every working professional in maritime settings should know to stay safe this summer:

Personal Flotation Devices (PFDs)

Personal flotation devices, such as life preservers, life jackets, or work vests, are indispensable for workers exposed to the risk of falling into the water. These PFDs must meet U.S. Coast Guard (USCG) standards, be well-maintained, and promptly replaced if any defects are identified. Proper fit and fastening are vital to ensure they remain secure and effective.

Visibility and Rescue Equipment

Enhanced visibility is crucial, especially in low-light conditions. Ensure that life jackets feature reflective material for better visibility. Additionally, well-marked life rings and lines along the dock, equipped with USCG-approved specifications, are essential for swift rescue operations. Basket stretchers, blankets, and other coverings for rescued individuals should also be readily available.

Emergency Access and Guarding

In the event of an emergency, access to fixed and portable ladders must be clear, well-marked, and maintained in good condition. Rescue ladders should extend sufficiently both above and below the water surface to facilitate safe retrieval. Furthermore, areas where workers are at risk of falling into the water should be appropriately guarded to prevent accidents.

For comprehensive guidelines on maritime safety, please refer to OSHA’s 29 CFR 1917 Marine Terminals. By adhering to these protocols and ensuring the availability of necessary equipment, employers and workers alike can mitigate risks and promote a safer working environment in maritime settings.

In the dynamic and challenging world of maritime work, prioritizing safety is not just a legal requirement but a moral obligation. By investing in proper training, equipment, and protocols, we can protect the lives and well-being of those who keep our waterway industries afloat, ensuring safety at maritime facilities.

As the temperature rises, so does the risk of heat-related illnesses. Whether you’re working outdoors or simply going about your daily work routine, it’s crucial to take precautions to protect yourself from summer weather conditions. Here are some tips for staying safe this summer.

Hydration: Quench Your Thirst, Protect Your Health

One of the most important steps you can take to prevent heat-related illnesses is to stay hydrated. When the mercury climbs, your body loses fluids through sweat, increasing the risk of dehydration. This can lead to serious conditions such as heat stroke or heat exhaustion.

The symptoms associated with heat stroke include confusion, loss of consciousness, and seizures. The symptoms associated with heat exhaustion include headache, nausea, dizziness, weakness, irritability, confusion, thirst, and heavy sweating. Immediately seek medical attention if you or your coworker experience these symptoms.

To stay properly hydrated, and avoid heat stroke or exhaustion, make sure to drink plenty of fluids throughout the day, especially if you’re engaging in physical activity. Water is always a good choice, but for longer periods of exertion (two hours or more), replenish with electrolytes from sports drinks, electrolyte-infused water, or coconut water. Remember to drink at least one cup (8 ounces) of water every 20 minutes while working in the heat to keep your body cool and hydrated.

Rest: Take a Break, Beat the Heat

In addition to staying hydrated, it’s important to give your body the rest it needs to recover from the heat. As temperatures soar, so should the frequency and duration of your breaks. Listen to your body and take breaks as needed, even if you’re tempted to push through the heat.

The length of your breaks will depend on various factors, including the environmental heat, your level of physical activity, and any personal risk factors you may have. Whenever possible, seek out a cooler location to rest, whether it’s in the shade outdoors, an air-conditioned vehicle or building, or an area with fans and misting devices.

Remember, skipping breaks in hot conditions is not safe, so prioritize your well-being and take time to rest as heat stress rises.

Shade: Find Shelter from the Sun

When working outdoors, seek shelter in shady areas to protect yourself from the sun’s harmful rays. Whether it’s under a tree, in a tent, or near a building, finding shade can provide much-needed relief from the heat. If you’re indoors, make sure to rest in a cool area away from heat sources such as ovens, boilers, or furnaces.

By following these tips for staying safe this summer, you can help reduce the risk of heat-related illnesses and stay safe while being productive during the summer months. Remember, water, rest, and shade are your best allies in the battle against the heat stress. Stay hydrated, take breaks as needed, and seek shelter from the sun to beat the heat and stay healthy all summer long.

Severe weather, such as a tornado, can strike at any time. It is important to understand severe weather warning systems, preparations, and the steps to take prior to and during severe weather.

Warnings and Watches

The National Weather Service Issues tornado watches and warnings. A tornado watch means that tornados are likely to occur in the watch area. During a tornado watch always be ready to act quickly, take shelter, and monitor radio and television stations for more information.

A tornado warning means that a tornado was sighted in the area. It can also mean that radar indicates the presence of a tornado. When warnings are issued take shelter immediately.

Preparation

It is important for employers to prepare for tornadoes. Preparation includes:

• Identifying shelter locations.
• Developing an accountability system for employees and visitors.
• Establishing or installing an alarm system to warn workers.
• Testing the alarm system at least twice per year.
• Developing methods to communicate warnings to those with disabilities or those who do not speak English.
• Assigning specific duties to workers in advance. This would include activities such as roll call, first aid, and monitoring the internet as well as radio or tv stations.
• Equipping shelter areas with supply kits. A supply kit should include first aid supplies, water, blankets, a radio, and a flashlight.
• Conducting routine severe weather drills or exercises.

Shelters

The best way to take shelter from a tornado is in an underground location. Examples include basements or storm cellars. If an underground shelter is not available:

• Seek a small interior room or hallway on the lowest floor possible.
• Stay away from doors, windows, and outside walls.
• Stay in the center of the room.
• Avoid rooms or buildings with wide span roofs.

If you are in a vehicle there are two options:

1. Stay in the vehicle with your seat belt on. Keep your head below the windows. Cover your head with your hands, a blanket, or a heavy jacket.
2. Locate an area which is noticeably lower than the roadway. Lie in that area and cover your head with your hands.

Source:  www.osha.gov/tornado/preparedness

Additional Links:

• Truck Driver Safety
• Severe Weather Safety Tips – weather.com
• Safety Made Simple – Catalog of Courses

Workplace safety accountability is a cornerstone of workplace safety and fosters a culture where safety protocols are not just followed but integrated into the daily operations of an organization.

Joe Mlynek, CSP, OHST, founder of Progressive Safety Services, LLC and co-owner of Safety Made Simple shares his research and work around employee engagement, responsibility and how accountability for personal safety can institute a culture of workplace safety. This seasoned agricultural safety professional takes a deep dive into defining safe behaviors, performance evaluations and the progressive discipline that can implement change in a recent National Grain and Feed Association webinar.

The Evolution of Workplace Safety Accountability

Mlynek opened the webinar by reflecting on the evolution of workplace safety accountability over the years.

“Ten years ago, we struggled to get people to attend a session like this,” he notes, highlighting the initial challenges in drawing attention to progressive safety topics such as accountability. However, he observes a significant shift in recent years, “We’ve already doubled our participation level today, versus ten years ago,” indicating a growing industry-wide recognition of the importance of best practices over mere compliance.

Defining Accountability in Safety

The definition of accountability isn’t blurry for Mlynek and he shares that it shouldn’t be for companies working to implement a stronger workplace safety culture, either. We all play a part – we’re all responsible for helping to ensure a safe workplace.

“Accountability is being responsible to someone or for some actions.” He emphasizes that accountability in the workplace transcends hierarchical boundaries, involving everyone from senior managers to frontline employees.

“When we look at who’s accountable for safety, the answer is everyone,” he asserts, underlining the collective responsibility for maintaining a safe working environment.

Strategies to Foster Workplace Safety Accountability

One of the key strategies Mlynek discusses is the establishment of clear expectations and the communication of these standards to all employees.

“Years ago when I worked for a large agribusiness company, they had an employee bill of rights as part of their mission statement,” he recalls, pointing out the importance of employees knowing what is expected of them and being held to those standards.

He also stresses the shift from compliance to commitment, where employees are encouraged to take ownership of safety issues and exceed expectations.

“With accountability, that’s the shift that we want to make,” Mlynek explains.

The Role of Feedback

Mlynek highlights the critical role of feedback in promoting accountability. He describes two types of feedback:

Positive Feedback — a reinforcement of good practices

Guidance Feedback — a crucial management tool when corrective actions are needed.

The CAR Model: A Framework for Delivering Feedback

One of the key highlights from Mlynek’s approach is the CAR model, which stands for Context, Action, Result. This model provides a structured framework for delivering feedback that is both constructive and empowering. By using this model, managers can communicate feedback in a way that is clear and impactful, making it easier for employees to understand their actions’ implications and the expected outcomes.

For instance, if an employee is observed using safety equipment correctly, a manager might say, “I noticed you were using your safety glasses and face shield while operating the grinder. This is great because it significantly reduces the risk of eye injuries, which are common with such equipment. Thank you for following safety protocols.”

This example of positive feedback not only acknowledges the correct action but also reinforces the safe behavior by linking it to a positive result.

Implementing Progressive Discipline

Discussing the implementation of progressive discipline, Mlynek clarifies that the goal is not to punish but to alter behavior to prevent safety incidents.

“The goal is not to punish the person, it’s really to change or alter their behavior,” he states. This approach involves a step-by-step escalation process, ensuring that employees have opportunities to correct their actions before more severe steps are taken.

Conclusion: The Impact of Accountability on Safety Culture

In conclusion, Mlynek’s insights shed light on the transformative power of workplace safety accountability in enhancing good safety practices. By establishing clear expectations, fostering commitment over compliance, effectively using feedback, and implementing progressive discipline, organizations can create a safety culture where accountability is deeply embedded.

“Accountability is a positive thing… as leaders in the safety arena, we need to understand that our teams want to succeed and we need to help them do so,” he shares.

His expertise and practical advice offer valuable guidance for organizations aiming to strengthen their safety protocols through the powerful tool of accountability.

Suggested Links:

• Safety Accountability In The Workplace
• How Do You Build A Safety Culture
• Course Catalog from Safety Made Simple

Stressed cattle can easily injure or kill a worker. According to the Kansas Livestock Association’s Work Comp Program, 45% of feedlot injuries involve working with cattle. Understanding cattle behavior and implementing low stress cattle handling practices can prevent serious injuries and fatalities. Low-stress cattle handling incorporates the understanding of cattle’s natural behaviors. Using this knowledge, cattle handlers can positively affect cattle movement.

Cattle Behavior

Contrary to widely held belief, cattle behavior is often predictable. Most handler related incidents occur when cattle are stressed. Understanding cattle stressors can reduce the potential for serious injuries and fatalities. Cattle are animals of prey and often defenseless. They need to trust their handlers. The trust established between handlers and animals reduces stress. Gaining trust requires cattle handlers to move in a predictable manner so that cattle feel safe.

The Flight Zone

Cattle handlers must understand and manage the flight zone. This is a significant and common cattle stressor. An animal’s flight zone is similar to your personal space. It is the distance from an animal that a handler must maintain for the animal to feel comfortable. When a person enters the flight zone, the animal will move. The flight zone radius can range from five to over 25 feet for feedlot cattle and as far as 300 feet for range cattle.

Low Stress Cattle Handling

Using consistent and predictable movements can significantly reduce flight zone distance and minimize animal stress. The objective of a cattle handler is to train the animals to move in a predictable manner. Approaching animals quickly or in an unusual or unpredictable manner can cause stress. Animals can also become stressed by unusual noises, mobile equipment movement,   and in new or unfamiliar environments.

Low stress cattle handling in feedlots requires predictable movements. Handlers must understand the unique flight zone for each a group of cattle. It takes time and patience to gain an animal’s trust. Earning their trust must begin as soon as they enter the feedlot. Trust is quickly lost whenever an animal feels threatened.

Conclusion

Implementing low stress cattle handling practices is the key to preventing serious injuries and fatalities in cattle feedlots. Safety doesn’t have to be difficult, simple steps, such as implementing low stress cattle handling practices, can prevent injuries and save lives.

Additional Links:

• How Do You Build A Safety Culture?
• Learn More About Safety Training for the Livestock Industry
• Full Course Catalog – Safety Made Simple

 

Chuck Pirie is the founder of Safety Made Simple, LLC and a livestock subject matter expert. He has over 30 years of experience in safety and as a consultant. Chuck can be reached at [email protected]

 

The majority of employees are aware of  fall hazards in their work environment. They also have knowledge in  fall protection strategies, required equipment, and inspection protocols. However, they are often unaware of orthostatic intolerance and suspension trauma.

Ortho Static Intolerance

Orthostatic intolerance is “the development of symptoms such as light-headedness, heart palpitations, poor concentration, fatigue, nausea, headache, sweating, weakness, and occasional fainting while standing upright.”  It results from blood accumulating in the leg veins. This can be caused by lack of  movement or the force of gravity.

Orthostatic intolerance requires the legs to remain relaxed, straight, tight, and below head level. Leg muscles contract while walking or shifting positions. This causes leg muscles to press against the veins in the legs pumping blood back to the heart. This is why orthostatic intolerance is uncommon during daily activities.

Circulation is reduced when blood accumulates in the legs. The body responds by speeding up the heart rate. This maintains blood flow to the brain. If blood flow is significantly reduced, speeding up the heart rate is not effective. In response, the body will abruptly slow the heart rate which reduces blood flow. Reduced blood flow to the brain can cause fainting or loss of consciousness.

Suspension Trauma

Death resulting from orthostatic intolerance is called suspension trauma. Consider a worker hanging in a body harness. The harness’s straps put pressure on the leg veins. This compresses the veins causing reduced blood flow to the heart. Without leg muscle contraction, blood flow to the heart will slow. This causes the worker to lose consciousness. Prolonged suspension can result in serious physical injury or even death. Research shows that suspension in a body harness can result in unconsciousness, and possibly death within 30 minutes.

Preventing Suspension Trauma

A worker can slow the onset of suspension trauma by pumping the legs while suspended in a harness. This activates the leg muscles which help pump blood back to the heart.

Suspension trauma straps are also helpful. They connect directly to the harness. The straps allow the worker to remain upright. This activates the leg muscles, reduces venous pooling, and restores blood blow to the heart.

Fall Rescue

Rescuing a worker quickly can prevent suspension trauma. The Occupational Safety and Health Administration (OSHA) requires that employers provide for “prompt rescue of employees in the event of a fall.” Prompt rescue may require an in-house rescue team or first responders. Rescuers utilize equipment such as ladders, ropes, and aerial lifts to rescue suspended workers.

Rescue personnel must be careful when handling an unconscious worker. The lethal surge of blood returning to heart is called reflow syndrome. Reflow syndrome occurs when a worker is removed from the harness and placed flat on their back. Rescuers must keep the worker’s upper torso upright at least 30-40 degrees. The worker can be positioned flat on their back over a 45-minute period.

Conclusion

It is important to plan for fall related emergencies. Evaluate activities that require fall protection equipment at your facility as well as your rescue plan. Make sure employees are knowledgeable of the dangers associated with suspension trauma. Never allow workers using fall arrest equipment to work alone and make sure they know what to do in the event of a fall. Remember, safety doesn’t have to be difficult, simple steps, such as educating workers on suspension trauma can prevent serious injuries and save lives.

Related Links

• Fall Protection Calculations
• Fall Protection Equipment Inspections
• Course Catalog – Safety Made Simple

References

• Raynovich, William. “Dangerous Suspension: Understanding Suspension Syndrome &Prehospital Treatment for those at Risk.” Journal of Emergency Medical Services 31 July 2009: 1-10. Print.
• Weems, Bill and Bishop, Phil “Will Your Safety Harness Kill You.”  Occupational Health and Safety (OHS) March 2003: Print.
• United States Department of Labor. (2011). Safety and Health Information Bulletin (SHIB-03-24-2011). Suspension Trauma/Orthostatic Intolerance. Occupational Health and Safety Administration.

 

Joe Mlynek is a partner and subject matter expert at Safety Made Simple, LLC. He has over 25 years of experience in safety at the corporate level and as a consultant. He is a Certified Safety Professional (CSP) and Occupational Safety and Health Technician (OHST). Joe can be reached at [email protected].

Phosphine has been used in the fumigation of grain storage structures since 1958. Available formulations include aluminum or magnesium phosphide. Both penetrate deeply into stored grain killing target pests. While licensed fumigators are highly trained in phosphine’s hazards, many affected employees and contractors working in close proximity to fumigated structures are not. This blog provides basic information for anyone working near structures fumigated with aluminum or magnesium phosphide.

Odor and Toxicity

Phosphine has an odor that is often compared to dead fish or garlic. The odor can be detected at low concentrations but should not be relied upon for warning purposes. Phosphine also has a specific gravity in air of 1.214 (air=1 @ standard temperature and pressure). Since phosphine is heavier than air it penetrates deep into grain. This also means that phosphine can settle in low lying interior areas lacking adequate natural or mechanical ventilation such as tunnels, basements, and boot pits.

Phosphine gas is generated when aluminum or magnesium phosphide is exposed to heat or moisture. Phosphine gas at certain levels can be toxic to humans. The Occupational Safety and Health Administration (OSHA) sets the Permissible Exposure Level (PEL) for phosphine at 0.3 parts per million (ppm). The PEL is the highest level of exposure an employee may be exposed to without incurring the risk of adverse health effects based on an eight-hour workday. Exposure to concentrations above the PEL requires NIOSH certified respiratory protection, such as a full-face respirator with an appropriate canister or cartridge.

Symptoms

Symptoms of low-level exposure to phosphine may include general fatigue, ringing in the ears, nausea, or pressure in the chest. These symptoms may occur immediately or several hours after exposure. Symptoms of exposure to greater quantities of phosphine may include fatigue, nausea, vomiting, diarrhea, and chest pain. Symptoms should disappear when the exposed person is removed to an area with fresh air. Should symptoms persist, the person should receive immediate medical attention.

Notifications

Employees working near fumigated structures must be notified that fumigation is in process. This can be accomplished by conducting routine safety meetings and placarding fumigated structures. The licensed applicator is required to post placards or signs at the entrances to the fumigated structure and  areas connected to the structure. These placards and signs warn affected employees of potential danger and the need to stay out of the area. Unauthorized persons should not have access to fumigated areas.

Fumigation Process

Once the fumigation process is complete the fumigator will ensure that the structure is adequately aerated so that affected persons are not exposed to residual phosphine. Areas adjacent to bins, silos, or fumigated structures should be ventilated using natural or mechanical ventilation. This can be achieved by leaving tunnel access hatches, windows, and doors open or by providing artificial ventilation with fans or blowers. Employees should be encouraged to use air monitoring equipment when entering recently fumigated areas. Monitoring for phosphine can be performed by using gas detector tubes or an air monitor equipped with phosphine sensing capability. Employees must never re-enter structures until the concentration of phosphine is less than its PEL (0.3 ppm).

Fumigant tablet canisters should be stored in a dry place protected area. Exposure to water or other liquids releases phosphine gas and may cause spontaneous ignition. The fumigant storage area should also be properly labeled. An NFPA diamond label on the exterior of the storage area will assist first responders by communicating  basic hazard information.

Remember, safety doesn’t have to be difficult, simple steps, such as training employees on fumigant hazards and how they can protect themselves, can prevent exposure and send people home safely.

Related blog articles:

• Confined Space Incidents
• Hierarchy of Controls
• Effective Workplace Communication Guide
• Full Course Catalog – Safety Made Simple

 

Joe Mlynek is a partner and subject matter expert at Safety Made Simple, LLC. He has over 20 years of experience in safety at the corporate level and as a consultant. He is a Certified Safety Professional (CSP) and Occupational Safety and Health Technician (OHST). Joe can be reached at [email protected]

Back when I played football I was on the “hands team.” The hands team was sent out on the field whenever there was the slightest chance our opponent would attempt an onside kick.  I don’t recall our opponents ever attempting an onside kick, but that didn’t stop our coach from practicing this every Thursday before our Friday night match up. He wanted us to be prepared for every scenario. A workplace emergency, similar to an onside kick, isn’t something that happens every day, but you want to be prepared regardless.

A workplace emergency is any unforeseen situation that threatens employees, customers, or the public, disrupts or shuts down operations, or causes physical or environmental damage. These emergencies can be human-caused or natural. Examples include floods, hurricanes, tornadoes, fires, toxic gas or chemical spills and releases, explosions, or workplace violence.

What Is An Emergency Action Plan?

An emergency action plan covers designated actions employers and employees must take to ensure employee safety from the types of emergencies that could impact the facility. The first step when developing an emergency action plan is to perform a hazard assessment to determine if any hazards in the workplace could cause an emergency. For instance, the presence of suspended combustible dust at certain concentrations in enclosed structures or equipment coupled with an ignition source can result in a dust explosion, hazardous chemicals when released can cause physical and health hazards to employees and the surrounding community, and natural disasters can occur about anywhere. At a minimum, each facility’s emergency action plan should include:

• The preferred method for reporting fires, explosions, chemical releases, and other emergencies.
• An evacuation procedure.
• Emergency escape procedures and route assignments such as floor plans, workplace maps, and safe refuge areas (evacuation points).
• The names, titles, departments, and telephone numbers of individuals both within and outside the company to contact for additional information or explanation of duties and responsibilities under the plan.
• Procedures for employees designated to perform or shut down critical plan operations, operate fire extinguishing equipment, or perform other essential services.
• Rescue and medical duties for trained employees designated to perform them.

The plan must also include the method for alerting employees of the emergency so that they can evacuate or take appropriate action. Employees can be notified by public address systems, portable radio units, or other types of visual or audible alarms. If alarms are used, they must be able to be heard, seen, or otherwise perceived by everyone in the workplace.

Developing an Emergency Action Plan

When developing the emergency action plan, it is important to determine the conditions requiring an evacuation, a clear chain of command, and a designated person or persons at your location authorized to order an evacuation or shutdown. Specific evacuation procedures must be incorporated to include designated emergency exit routes, exits, and evacuation point(s). It is also important to designate which employees will continue to shut down critical operations during the evacuation and an accountability system to ensure that facility personnel are safely evacuated.

The plan must designate a primary coordinator to lead and coordinate the implementation of emergency procedures including notification of first responders. There should also be another who can fill in if the primary coordinator is not available. The coordinator is responsible for determining:

• whether an emergency exists that requires the activation of the emergency procedures within the plan,
• supervising response efforts, coordinating with emergency services such local fire departments,
• and directing plant shutdown operations.

Employee Understanding and Training

Employees must understand the function and elements of the emergency action plan. This includes the types of emergencies that could happen at the facility, reporting procedures, types of alarm and notification systems used, evacuation procedures including evacuation points and shutdown procedures, and any special hazards at the facility. Employee training should address:

• Individual roles and responsibilities.
• Notification, warning, and communication procedures.
• Emergency response procedures.
• Evacuation, shelter, and accountability procedures.
• The locations of emergency equipment.
• Emergency shutdown procedures.

Training should be conducted annually with all employees and whenever new employees are hired.  Training should include:

• new equipment, materials or processes that affect evacuation routes,
• any changes in the layout or design of the facility,
• and whenever emergency procedures are updated or revised.

It is also recommended that emergency evacuation drills be performed routinely throughout the year for the specific types of emergencies identified within the plan such as fires, hazardous chemical releases, and severe weather.

Conclusion

Developing an effective emergency action plan is a critical step in the emergency planning process. Review your plan annually. Ensure that it covers the potential emergencies that could happen at your facility and practice your response procedures. Emergencies can come when you least expect it, be ready for the onside kick.

Related Links:

• Don’t Get Caught In The Line of Fire
• Preventing and Responding to Grain Dryer Fires
• Full Course Catalog – Safety Made Simple

Sources:

The Occupational Safety and Health Administration. How to Plan for Workplace Emergencies and Evacuations. US Department of Labor, 2001. https://www.osha.gov/sites/default/files/publications/osha3088.pdf

 

Joe Mlynek is a partner and subject matter expert at Safety Made Simple, LLC. He has over 25 years of experience in safety at the corporate level and as a consultant. He is a Certified Safety Professional (CSP) and Occupational Safety and Health Technician (OHST). Joe can be reached at [email protected]

Grain dryer fires pose unique hazards to the grain handling industry. These fires can result in downtime, lost revenue, injury and possible death. It is imperative that each facility engaged in grain drying, develop and document an effective emergency response plan to deal with these incidents.

Causes

Grain dryers move high volumes of air through perforated screens that allow air to flow through the grain. Grain dryer fires are often caused by lack of operator training, lack of operating oversight, inadequate cleaning and running the dryer at high temperatures. It is imperative that each operator is properly trained on the operation of the dryer. Established operating procedures can be found in the equipment’s operations manual.

Prevention

Implementing a grain dryer preventive maintenance program reduces the likelihood of a dryer fire. The dryer’s operations manual includes preventive maintenance schedules that should be followed. Each grain dryer should have its own maintenance schedule utilizing a maintenance checklist. Preventive maintenance should be performed prior to, during, and after the drying season. Many dryer fires are the result of improper in-season maintenance. In-season maintenance activities should include routine cleaning of the dryer screens and inspection of emergency controls and associated equipment.

Emergency Response

Each facility engaged in grain drying should develop an emergency response plan specific to fires. The response plan will vary based on the type, manufacturer and model of grain dryer. The response plan should be included in the facility’s emergency action plan. Generally accepted emergency response actions include the following:

Notify the Fire Department

The first step when responding to a dryer fire involves notifying the local fire department. Many dryer fires are small in nature and can be extinguished quickly by facility personnel. However, some dryer fires spread rapidly and require additional resources. Regardless of the size of the fire, it is important to have the fire department on stand-by when implementing the dryer’s emergency response plan. This saves valuable response time should the fire spread rapidly beyond control.

Isolate the Equipment

Grain dryers are equipped with emergency shut-offs located at the dryer control panel or at the PLC controls. The emergency-stop button will shut-off critical equipment such as the gas supply, burner, blower/fans, unload conveyors and the wet and dry legs. Grain should never be cooled with fans. This supplies the fire with more oxygen causing it to spread rapidly. After depressing the emergency-stop button, verify that the appropriate equipment is isolated. Some dryers may require manual shut-down of both the electrical and fuel supply. Consider locking and tagging out all associated electrical isolating devices and the gas supply in order to isolate the equipment during emergency response activities.

Determine the Location of the Fire

In the event that the fire is small, it may be extinguished with an at-hand fire extinguisher, fire hose, or by removing the grain through the dryers unloading system. When using the unloading system, it is important to drain the column impacted by the fire as well as the adjacent columns. Opening dryer discharge gates can expose employees and first responders to hot material. Using long handled tools to actuate column discharge gates can prevent exposure to extreme temperatures. Proper PPE, such as turn-out gear or heat resistant personal protective equipment (PPE), should be worn. If the facility does not have the appropriate PPE, consider requiring the fire department to open the discharge gates. Avoid using conveyance and bucket elevators to move smoldering grain. Smoldering or hot material reclaimed from the dryer should be extinguished under the direction of facility management or the responding fire department.

Inspect Attached Equipment and Implement a Fire Watch

Attached equipment including the destination bin, conveyance, bucket elevator legs, etc. should be inspected to ensure that hot material is not present. Implement an adequate “fire watch” for the remainder of the operating period to identify any hot spots within the system.

Conclusion

Establishing an effective preventive maintenance program can prevent dryer fires. Should a fire occur, a documented response plan can prevent the fire from spreading, protect property and eliminate the potential for injury. If your facility does not have a dryer fire response plan, consider developing one with the assistance of the dryer’s manufacturer, property insurer, and the local fire department. Once the plan is established, invite the local fire department to the facility. Discuss prevention strategies and the procedure for responding to a dryer fire. The time to get to know the local fire department is prior to an incident, not during it. Remember, safety doesn’t have to be difficult, simple steps, such as establishing a routine cleaning and maintenance schedule, can prevent grain dryer fires.

Related Links:

• Off The Job Safety Programs
• Emergency Action Plans
• Full Course catalog – Safety Made Simple

 

Joe Mlynek is a partner and subject matter expert at Safety Made Simple, LLC. He has over 25 years of experience in safety at the corporate level and as a consultant. He is a Certified Safety Professional (CSP) and Occupational Safety and Health Technician (OHST). Joe can be reached at [email protected]

Mobile cranes are used in various industries for maintenance and construction related projects. Whether you work for a construction company or host employer, it is important to understand the basic requirements. This blog will discuss several important operating requirements outlined in OSHA 1926, Subpart CC, Cranes and Derricks in Construction.

Ground Conditions

Ground conditions can negatively affect a mobile crane’s capacity and stability resulting in collapse, employee injuries, and property damage. The ground must be firm, drained, and graded. Supporting materials such as blocks, mats, or cribbing must be used in certain situations to ensure stability.

The OSHA standard places the responsibility for ensuring adequate ground conditions with the “controlling entity” at the site. This entity can be the general contractor, construction manager, or other legal entity with overall responsibility for the project’s planning, quality, and completion. The controlling entity must also inform the mobile crane user and operator of hazards beneath the equipment including voids, tanks, and utilities.

Power Lines

Electrocutions can be caused by a mobile crane, load, or load line contacting a power line. The OSHA standard contains specific procedures that employers must follow when operating mobile cranes near power lines. Prior to operating a crane on a work site, the employer must evaluate whether power lines are present in the work area and whether crane operations will come within 20 feet of a power line. If operations will not come within 20 feet during the project, no further precautions are required. If the initial plan for the crane’s use changes, the work zone must be reevaluated.

The standard also provides an alternate requirement if the lines voltage is known. Line voltage is determined by contacting the utility provider. Once the lines voltage is determined, the minimum clearance distance in OSHA 1926.1408, Table A can be used:

Should any part of the mobile crane, load, or load line come closer to the power line than the minimum clearance distance (either 20 feet or Table A clearance) the line must be de-energized and grounded, or specific steps must be identified and implemented to maintain the required minimum clearance distance. Required steps include conducting a pre-planning meeting, using non-conductive tag lines, erecting and maintaining an elevated warning line, barricade, or line of signs with flags or similar high-visibility markings at the minimum clearance distances. In addition, at least one of the following measures must be implemented: use of a dedicated spotter, use of a proximity alarm, use of a range control warning device, use of a device that automatically limits the crane’s range of movement, or use of an insulating link or device installed between the end of the load line and the load.

Rated Capacity Compliance

Mobile cranes can collapse when their rated capacity is exceeded. The term rated capacity is defined by the OSHA standard as the maximum working load permitted by the manufacturer under specified working conditions. These working conditions typically include a specific combination of factors such as equipment configuration, radii, boom length and other use parameters. The weight of the load must be determined prior to the lift and the crane must never be operated in excess of its rated capacity.

Conclusion

Mobile crane operations can negatively affect workers’ safety and result in property damage and regulatory exposure. This blog highlighted several, but not all, of OSHA’s requirements for employers. The information within this article, as well as additional crane requirements, can be found in OSHA 1926 Subpart CC, Cranes and Derricks in Construction. Another excellent resource is OSHA’s Small Entity Compliance Guide for the Final Rule for Cranes and Derricks in Construction.

Additional Links:

• Fall Protection Calculations
• Don’t Get Caught In The “Line of Fire”
• Full Course Catalog – Safety Made Simple

 

Joe Mlynek is a partner and subject matter expert at Safety Made Simple, LLC. He has over 25 years of experience in safety at the corporate level and as a consultant. He is a Certified Safety Professional (CSP) and Occupational Safety and Health Technician (OHST). Joe can be reached at [email protected]

The National Institute for Occupational Safety and Health (NIOSH) estimates that about 2,000 U.S. workers sustain job-related eye injuries requiring medical treatment each day. While many of these injuries are caused by small particles striking or abrading the eye, many are also caused by exposure to hazardous chemicals. Emergency eyewash and shower units play a significant role in minimizing the severity of eye injuries resulting from exposure to hazardous chemicals.

OSHA and ANSI Requirements

In the United States, the Occupational Safety and Health Administration (OSHA) requires that “where the eyes or body of any person may be exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body shall be provided within the work area for immediate emergency use.” The American National Standards Institute (ANSI) similarly requires that employers provide eyewash and shower equipment where employees are exposed to hazardous materials. It is up to the employer to determine their level of exposure and the need for emergency equipment such as an eyewash or emergency shower.

Emergency Eyewash stations and showers are either connected to a continual source of potable water or self-contained, gravity fed units. Self-contained units contain their own flushing fluid that must be refilled or replaced after use. According to ANSI, emergency eyewashes and showers must be located in an area that requires no more than 10 walking seconds to reach or within 55 feet of the hazard, located in a well-lit area identified with a sign, located on the same level as the hazard, and equipped with enough tepid water for 15 minutes of continuous use. If shut off valves are installed in the unit’s supply line for maintenance purposes, provisions must be made to prevent unauthorized shut-off.

Accessibility

It is important that emergency showers and eyewash units are accessible. Obstacles in the travel path can delay response time. Seconds count when the eyes and skin are exposed to corrosive or caustic liquids or other hazardous materials. Some hazardous chemicals take only 6 to 8 seconds to penetrate the outer membrane of the eye. For skin exposure, a worker might have between 10 to 15 seconds before severe damage occurs.

Inspection

Emergency eyewash and shower units must be inspected and tested on a routine basis. Without regular maintenance, inspection and testing, the water required to flush a worker’s body or eyes could become contaminated with particulates or chemicals or fail to function all together. When inspecting emergency eyewash and shower units, the inspector should make sure the unit is accessible and the unit’s sign is visible. The unit’s water source must be turned on and the water flow must be adequate, clear. The unit must remain on until the unit is turned off. The water should also be tepid. Tepid is considered as a temperature between 60- and 100-degrees Fahrenheit (16-38 degrees Celsius). Temperatures higher than 100 degrees Fahrenheit can enhance a hazardous chemical’s interaction with both the skin and eyes.

Educating Employees

Employees must have a good understanding of emergency eyewash and shower use. This can be achieved with a simple five-minute discussion and demonstration. When using an eyewash station or emergency shower the process involves:

1. Pushing or pulling the handle to activate the water flow.
2. Removing contact lenses and clothing if applicable. Contact lenses can trap hazardous chemicals in the eyes and prevent the eyewash from washing out the hazardous chemical. Similarly, clothing can trap hazardous chemicals close to the skin. The eyes will naturally want to close. Holding the eyes open will allow adequate flushing.
3. Flushing the eyes and skin for at least 15 minutes.
4. Seeking further medical attention.

It is also important for workers to understand how to respond when another employee’s eyes or skin are exposed to hazardous chemicals. In the event of an emergency, coworkers should help the exposed worker get to the eyewash or shower and turn it on. Help the exposed worker hold their eyes open, remove contaminated clothing, and call for medical assistance. While it can seem like an eternity, they must make sure to flush the eyes and skin for at least 15 minutes. In the event that emergency services are called, noting the chemical’s name, and providing the appropriate safety data sheet is helpful for those administering treatment.

Conclusion

Emergency equipment such as eyewashes and showers are no substitute for safe work procedures and personal protective equipment. However, should the unthinkable happen, properly maintained equipment can minimize injuries resulting from chemical exposure. Remember, safety doesn’t have to be difficult. Simple steps such as inspecting and maintaining emergency eyewashes and showers, can prevent serious injuries.

Related Links:

• Root Cause Analysis:  The Five Why’s
• Commitment vs Compliance
• Full Course Catalog – Safety Made Simple

References:

• EHS Today “Protecting Those Peepers: A Guide to Eye Wash and Emergency Shower Stations”
• Paul Lawton, “What Workers Need to Know About Eyewashes and Safety Showers” March 25,2014
• EHS Today “A Logical Approach to Emergency Shower and Eyewash Choices” www.ehstoday.com/print/content/21915183

Hazard monitoring equipment can prevent grain dust explosions, save lives, and protect your facility from collateral damage. I have always referred to these systems as “cheap insurance.” The up-front investment pales in comparison to the impacts an explosion has on employees, facility infrastructure, and business interruption.

Ignition Sources

There are three primary ignition sources that can ignite suspended dust within the confinement of a bucket elevator. These ignition sources include heat generated by the belt slipping on the head pulley, the belt rubbing against the bucket elevator’s casing, and overheated bearings. Research indicates that the majority of grain dust explosions can be traced back to these three ignition sources.

Belt Slip

Belt slip occurs when the belt is loose or overloaded. It can only be detected by monitoring the speed directly from the belt or indirectly by monitoring the boot pulley rotations per minute (rpm). A 3-phase induction motor runs at a constant speed independent of its load. Therefore, a single sensor can be used to detect belt speed. The sensor is usually mounted by the boot pulley to detect the rpm of a target attached to the shaft or on the casing to detect the speed of the passing bucket’s bolts.

OSHA establishes requirements for belt speed detection in standard 1910.272 – Grain Handling Facilities. The standard requires employers to equip inside bucket elevators with a motion detection device that will shut down the bucket elevator when the belt speed is reduced by no more than 20% of the normal operating speed. An inside bucket elevator is a bucket elevator that has the boot and more than 20 percent of the total leg height (above grade or ground level) inside the grain elevator structure. Bucket elevators with leg casings that are inside of rail or truck dump sheds, with the remainder of the leg outside of the grain elevator structure, are not considered inside bucket elevators.

The OSHA requirement for belt speed detection does not apply to grain elevators having a permanent storage capacity of less than one million bushels, provided that daily visual inspection is made of bucket movement and tracking of the belt.

Belt Rubbing

Bucket elevators have sidewalls or casings that misaligned belts can rub against. Heat generated by the frictional rubbing can ignite dust inside the bucket elevator. Limit switches, brass rub blocks, optical sensors, non-contact sensors, and solid-state touch switches are used to detect improper alignment. OSHA standard 1910.272 – Grain Handling Facilities requires that inside bucket elevators be equipped with a belt alignment monitoring device which will initiate an alarm to employees when the belt is not tracking properly.  Or, be equipped with a means to keep the belt tracking properly. The requirement for belt alignment monitoring does not apply to grain elevators having a permanent storage capacity of less than one million bushels. This is provided that daily visual inspection is made of bucket movement and tracking of the belt.

Bearings

Bearings create frictional heat when running. When properly lubricated, bearings usually run below the temperatures needed to ignite grain dust. If the bearing’s lubricant fails, heat can build up rapidly. This can ignite dust that has accumulated on or around the bearing or transfer heat to the interior of the bucket elevator. Bearing temperature monitoring systems monitor bearing temperature continuously. These systems consist of a bearing sensor mounted to the bearing housing and wired to an alarm control panel or programmable logic controller (PLC).

OSHA standard 1910.272 (link)

Grain Handling Facilities requires that bearings on inside bucket elevators be mounted externally to the leg casing. If this is not the case, the bearing must be equipped with temperature monitoring, vibration monitoring, or other means to monitor the condition of those bearings mounted inside or partially-inside the leg casing.

There are additional exceptions within the standard that negate the requirement for belt speed, belt alignment, and bearing temperature monitoring. One exceptions is for bucket elevators equipped with an operational fire and explosion suppression system capable of protecting at least the head and boot section of the bucket elevator.  Another exception is when bucket elevators are equipped with pneumatic or other dust control system methods that keep the dust’s concentration inside the bucket elevator. The concentration inside the bucket elevator must be at least 25% below the lower explosive limit at all times during operation.

Today’s hazard monitoring systems can incorporate inputs from a number of different sensors such as belt speed, belt alignment, and bearing temperature. The system can be read from a wall mounted control panel, computer, and even a mobile phone app. Systems can also be interlocked to shut down the bucket elevator leg as well as upstream and downstream equipment. Hazard monitoring systems require regular preventive maintenance and inspection to ensure proper operation. The system should be tested in accordance with the equipment manufacturer’s requirements.

Conclusion

It is important that operations employees understand the purpose and importance of hazard monitoring equipment. It may save their life. Train employees to shut down equipment when the hazard monitoring system indicates a hazardous condition. Employees should also:

• refrain from bypassing or turning off the system,
• notify management if the system is not working correctly or damaged during housekeeping and maintenance activities, and,
• never disregard an alarm or hazardous condition.

Hazard monitoring systems are an effective means to prevent grain dust explosions. Many companies have expanded these systems to include exterior bucket elevators and interior/exterior conveyance. These systems provide a greater level of safety and a form of “cheap insurance.”

Related Links:

• Harvest Safety Strategies
• Combustible Dust in Agriculture and Processing Facilities
• Full Course Catalog – Safety Made Simple

 

Joe Mlynek is a partner and subject matter expert at Safety Made Simple, LLC. He has over 20 years of experience in safety at the corporate level and as a consultant. He is a Certified Safety Professional (CSP) and Occupational Safety and Health Technician (OHST). Joe can be reached at [email protected]