造纸安全防护指导.doc

造纸安全防护指导在造纸行业中识别最好的方法2005 liberty mutual group - all rights reserved目录造纸安全防护的方法: 通则. 1流浆箱和成型器 . 8压榨 . 15烘缸. . 21压光机. . 29卷曲和纸筒 . 33复卷 . 38浆池类 . 44roll wrap . 48converting . 52beater and recovery . 56appendix a 安全防护方式. 59appendix b 滑到预防方式 . 79appendix c 机器控制方针. 85appendix d 静电控制. 88appendix e- 受限空间进入 . 90appendix f- 造纸安全标准92recommended safe work guidelines for paper making operations2005 liberty mutual group - all rights reservedthe illustrations, instructions, and principles contained in the material are general in scope and,to the best of our knowledge, current at the time of publication. there is no attempt to interpretany referenced codes, standards, or regulations. please refer to the appropriate code-,standard-, or regulation-making authority for interpretation or clarification (e.g., us, european,canadian, or iso standards).recommended safe work guidelines for paper making operations2005 liberty mutual group - all rights reservedapproaches to paper making safeguarding:general principlesthe paper machine and associatedoperations are hazardous due to their basicnature of high speed and pressure in-runningrolls, elevated temperatures, wet and slipperyconditions, and limited visibility areas. add tothese physical conditions the need tomanually feed, adjust, and observe the papermarking process at many locations on themachine, often while the machine is running,and one canunderstand thedifficultiesencounteredwhenattempting todesign andspecific safeguarding should then bedesigned, constructed, and installed.consensus standards have been referencedthroughout this document whenever possible.safeguarding must be feasible andappropriate, so that employees will not try toremove a guard that seems impractical.some safeguards and retrofit kits may beavailable from the original equipmentmanufacturer. after installing safeguards, besure to monitor their effectiveness todetermine if modifications are necessary.the three most recognized methods ofsafeguarding machinery are:providesafeguards.because of the numerous in-running roll nipseliminating the hazardguarding of the hazardwarning of the hazardand rotating machines, much of the followingdocument will deal with safeguarding thesehazards. before addressing each section ofthe paper machine individually, it is importantto summarize some general concepts ofmachine guarding that will be applied.a primary objective of machine safety is tonever allow personnel to enter or access ahazardous area while the machine isoperating. at the same time, it must berecognized that wide variations in papermachine configurations exist, as does theneed to provide access to each portion of themachine and its related power transmissionequipment.general safeguarding approacheshazards on your mills paper machinesshould first be identified and prioritiesestablished for safeguarding, based on theseverity of the exposure and likelihood ofcontact. a job safety analysis (jsa) orelimination of a hazard by design is the mostpreferable, but in many situations it is notfeasible. the second approach of guardingthe hazard is more commonly found inindustry. warning of the hazard is the thirdapproach, but it does not prevent access tohazards such as in-running nip points. it isalso possible to use a combination ofguarding, warning signs, and safety colors tohelp increase the effectiveness of thesafeguarding.additional safety considerationsthere may be cases where it is not practicalto completely guard a machine. in thesesituations, develop supplementary protectionsuch as providing automatic feedingmethods, hand tools, and personal protectiveequipment. this is in addition to employeetraining, good housekeeping, preventivemaintenance, and checking other items suchas lighting and floor conditions.other hazard identification method can helpyou systematically determine hazards,controls, and safe work procedures. look atother factors as well, such as improvingergonomics and minimizing occupationalhealth exposures.recommended safe work guidelines for paper making operations - 2005 liberty mutual group - all rights reserved1general principlesalso, it is highly probable that many goodideas and safeguarding designs will bedeveloped, or already exist, to control eachidentified hazard. share successful ideaswith other departments and facilities. learnfrom each others mistakes and successes.safeguarding methodsthere are six different methods ofsafeguarding machines that will be illustratedhere:these methods are listed in descendingorder of preference. the first three methods(fixed, interlocked, automatic) describeguards that are physical enclosures orbarriers that prevent entry of hands, fingers,or other parts of the body into a hazard byreaching through, over, under, or around theguard.guards should create no additional hazardsbetween themselves and moving parts. theyshould utilize fasteners not easily removableby personnel, except for authorized.5.6.fixed (structural barrier) guardsinterlocked guards and gatesautomatic safeguardssafeguarding devices (presence sensing)safe distancesafe locationindividuals. several types of guards aresuitable depending on how and where theyare used.the latter three methods of safeguardingdevices, safe distance, and safe locationshould be explored only when effectiveshields also offer some protection betweenthe hazard and the exposed worker; howeverit is not a common application the papermaking industry. this method offers littleresistance- in some cases, it is the onlybarrier of protection as it offers incompleteguards are not feasible- controlling access,not preventing it.refer to appendix f for additionalreferences, regulations, and standards thatmay apply to your operations.isolation of the hazards, and still allows one(at will) to reach over, under, or around toovercome that protection. therefore, shieldswill not be among those devices orsafeguards examined here.recommended safe work guidelines for paper making operations - 2005 liberty mutual group - all rights reserved2general principles防护举例固定防护fixed guards when properly designed,installed and maintained have the followingcharacteristics:figure 1. fixed transmission enclosure guard.figure 2. fixed coupling guard over drive shaft onembosser power transmission flywheel.considered preferable to other types.may be adjusted; once adjusted shouldremain fixed, and there should be nomovement or detachment.complete enclosure guards arepreferable whenever possible. if they arenot practical or significantly interfere withthe safe operation of the machine, barrierguards such as bar, rod, or partialenclosures may be installed. somebarrier guards provide side protection andothers may extend across the entire widthof the roll nips.some fixed guards are installed at adistance from the point of operation toallow for passage of materials or tools. atable of safe distances with permissiblefixed guard opening sizes is contained inappendix a, drawing a1 of this guide.extension of lubrication fittings throughthe guard eliminate the need foroperators to be in close proximity ofmachine hazards. see appendix a,drawing a9, for instance.figure 3. fixed shaft coupling guard for roller winderrecommended safe work guidelines for paper making operations - 2005 liberty mutual group - all rights reserved3general principlesmore fixed guardsfigure 4. fixed slitter guards inside re-winder.figure 5. fixed barrier guard.recommended safe work guidelines for paper making operations - 2005 liberty mutual group - all rights reserved4general principlesinterlocking guards and gatesif a fixed guard cannot be used, the firstalternative is an interlocking guard or gate. itprevents operation of the control(s) that startthe machine in motion, until the guard or gateis in the closed position. when it is open anddangerous parts are exposed, the startingmechanism is inoperable and prevents themachine from running. when the machine isin motion, the guard or gate cannot beopened.figure 6. interlocking guard on backend of re-winder,in the up” position.an effective interlocking guard or gate mustmeet three requirements:guard the dangerous part(s) before themachine can be operated.stay closed until the dangerous part(s)are at rest.prevent operation of the machine if theinterlocking device fails.figures 7 and 8 (below). re-winder safety trip wiredevice.figure 8- close up of interlocked trip wire at rewinderposition.figure 8a- sample interlock devicerecommended safe work guidelines for paper making operations - 2005 liberty mutual group - all rights reserved5general principlessafeguarding devicesa safeguarding device may be used whereeffective guards cannot be installed. asafeguarding device provides protection by:preventing and/or stopping normalmotion of the power transmission source,if personnel inadvertently enter thehazardous area.stopping the system in the event ofinadvertent entry into the hazardous area.figure 9- close up of presence sensing light beamlocated at rewinder position.automatic threaders, tail cutters, and reelturn-up safety devices eliminate the need forthe operator to be in close proximity to themachine hazards.in selection and design of presence-sensingand emergency stop devices, it is imperativeto consider the stopping time of the movingmachinery hazards. devices are appropriateonly for equipment capable of instantaneousstopping or adequate braking distance.figures 10. an example of a light curtain providingoperator protection at the re-winder end where the endroll is awaiting the interlocked guard (orange) fromraising into position. note the red circle around thelight beam transmitter and the red arrow pointing to thetrip wire interlock device.figure 10a- example light curtain on a mechanicalpower press- transmitter and receiverrecommended safe work guidelines for paper making operations - 2005 liberty mutual group - all rights reserved6general principlessafe distanceguarding may be accomplished bymaintaining a safe distance betweenpersonnel and the hazardous equipment.this safe distance can be provided in thefollowing ways:figure 11. guarding against access to machinery isaccomplished by providing the catwalk at a safedistance from the machinery.provide a minimum vertical distance of84” above the walking or working surfaceand the hazard.provide a minimum horizontal distance of42” between the person and the hazard.see appendix a, drawing a1 for moredetails on guard design.where possible, sources of mechanicalmotion should be located within theframework and structure of the machine,equipment or system.safe locationsafeguarding by location can beaccomplished by:figure 12. illustrates safeguarding by location by usinga fence enclosure to prevent access to the machinelocation in a room or similar enclosure.permanent, substantial partitions orscreens. any gap openings in partitionsor screens shall be of a size and locationso that persons cannot come into contactwith hazardous moving parts. seeappendix a, drawing a1 for moredetails.hazards.figure 13. areas accessed by balcony or elevatedplatform, restricted to trained workers.these areas are not normal workstations.recommended safe work guidelines for paper making operations - 2005 liberty mutual group - all rights reserved7head box and fourdrinierthis section contains alternative recommendations for each exposure. the configuration of the specific papermachine may determine which recommendations may be feasible for implementation or modification.potential safety exposuresthe primary exposures of the head box andfourdrinier are hazardous footing due to thecontinuously wet environment and access to movingmachine parts. the exposures mentioned in thissection include:head box top access: platform and ladderfourdrinier nip hazards: wire screen, dandy roll,support and tension roll, couch roll, anddoctor bladeswalkways and passageways: wire andpit, trim squirt, and floorsrotating hazards: couplings, shafts, andshaft endshead box - top accessplatformslip and fall hazards exist due to the wetenvironment. since the operator must makehead box adjustments, it is important to haveslip-resistant catwalks or platforms ofadequate width with top-rails, mid-rails, andtoe-boards.figure 14. head box platform. install an elevated catwalk across thehead box that has a slip-resistant surface,such as an open grating design. an elevatedcatwalk should be equipped on both sideswith standard railings top-rail; (42”), mid-rail(18”), and toe-board (4”). install railings at theends of catwalks or platforms that do not havestairs or ladders. design catwalks to avoidinterfering with operator adjustments on thehead box. see appendix b, drawings b1and b4 for additional information ondimensions and construction features.recommended safe work guidelines for paper making operations - 2005 liberty mutual group - all rights reserved8head box and fourdrinierladderslip and fall hazards may exist on the laddersleading up to catwalks and work platforms.the ladder should be slip-resistant, and havean adequate width, angle, and handrails.install properly angled head boxplatform access ladders that have a slip-resistant surface, such as an open gratingdesign. they should be equipped withstandard handrails on both sides of thefigure 15. head box platform access ladder withhandrail and slip-resistant surface.ladders. if the ladders extend too far into themain aisleway, replace with permanent stairsinstalled perpendicular to the platform. seeappendix b, drawings b2 and b3 foradditional information on dimensions andconstruction features.fourdrinier - nip hazardswire screennip hazards exist where the wire screencontacts the rotating rolls on both the frontand back sides of the fourdrinier.install a fixed side barrier guard ateach location where the wire screen contactsthe rotating rolls to prevent fingers and handsfrom contacting the nips. see appendix a,figure 16. front side view of the edge of the wirescreen.drawings a10 and a11 for additionalinformation.orinstall a standard railing to preventaccess to the nip points and the side of themoving screen. it should have a mid andlower rail to prevent employees fromaccidentally slipping and falling into the pit.the railings should allow for washing machinecomponents without having to remove fixedguards. they should be removed for machinemaintenance, but should be in place duringmachine operation. see appendix b,drawing b4 for additional inf