Safety

Tube Mill Safety

Safety Instructions for In-Plant Safety

Safety in your plant is of the utmost importance. It is vital to establish and enforce policies to insure that all equipment and machinery are operated and maintained in a safe manner. Compliance with federal, state, county, and local ordinances related to safety is essential.

The following pages contain suggestions to aid you in establishing an effective safety program. These suggestions should be reviewed by the appropriate personnel in your plant. Alternations may be required to suit your specific operation. It is suggested that your companies safety policies and procedures be posted public and be given to personnel concerned.

The suggestions are divided into three groups: Supervisory Personnel, Operator Personnel, and Maintenance Personnel. In order to define the limitations and responsibilities of each group, the personnel in each group must be aware of and implement your company’s safety policies and procedures.

In order for any safety program to be effective, it must start “at the top”. The time and cost necessary to establish an effective safety program is small, when compared to the time lost due to injuries and the related costs.

Please implement your safety program. Instruct and check your personnel of safe and proper methods, and working conditions to protect against accidents.

SAFE OPERATION

All supervisors, operations personnel, and employees associated with this equipment, should be fully instructed in its operations and use.

All involved personnel should have read the service manual and be knowledgeable in company safety procedures, regulations, and policies. On the job training, safety classes, safety programs, and safety inspections should be made available to all personnel.

Specific recommendations pertaining to the safe operations of this equipment are made at applicable points in this manual. The following general safety rules should be observed at all times.

T & H LEMONT, INC. assumes no responsibility in connection herewith. Nor can it be assumed that all acceptable safety measures are contained in this manual, or that other additional measures may not be required under particular or exceptional circumstances or conditions.

SAFETY INSTRUCTIONS FOR THE
SUPERVISORY PERSONNEL

The “supervisor” is the “key person” in plant safety. It is his/her responsibility to see that all employees know, understand, and obey all safety rules and practices. The supervisor’s primary responsibility is to see that his/her employees work in a safe manner.

Guidelines for Supervisory Personnel

1. One of the most important things a supervisor can do is to explain the need for safety. Employees will cooperate better if they understand how safety regulations can help them in performance of their duties.

2. Safety regulations need to be uniformly enforced. If exceptions are made in any area, the whole safety program will suffer. Know and obey all general safety rules currently in effect in your plant. Follow instructions. Clarify them if you are unsure or not clear about a procedure.

3. Setting a good example is an effective way to let your employees know that you are concerned about everyone’s safety.

4. Supervisors are to frequently “inspect”; noting and correcting unsafe conditions, unsafe practices, or unsafe actions by personnel.

5. Be observant for unusual noise, oil leaks, water leaks, air leaks, or other abnormal situations, and if they exist, take actions to correct them.

6. Take proper steps to protect hands and bodies from material during the thread up operation.

7. Check the operation of tube mill system in the manual modes, before placing equipment in the automatic or continuous mode.

8. Be certain all safety guards and devices are in place and are in good condition before starting work. GUARDS ARE EFFECTIVE ONLY WHEN THEY ARE IN PLACE. Do not allow equipment to be tested, adjusted, or put into operation with a guard or other safety device removed, or otherwise defeated. Do not allow them to be defeated or by passed.

9. Hands should be kept clear of all moving parts when the Tube Mill Line is running. If a roll adjustment is necessary while the Tube Mill Line is operating, it should be made with the utmost care to avoid contact with moving components or material.

10. Do not try to clear an obstruction or jam up while equipment is in operation.

11. Do not clean the equipment while turned on and/or in operation.

12. Gloves and/or articles of loose clothing must be kept clear of moving rolls and material when the Tube Mill Line is running.

13. Properly lock out the machine for adjustment and repair.
- Exceptions are noted in the specific adjustment procedures.
- Be aware and look out for the “other guy”.
- Use padlocks and safety lockout tags as required.
- Follow “Live Work Procedures” as defined in your company’s safety regulations when air, pump, or electrical power must be “ON” for adjustment or repair.

14. Before taking any action, analyze what effect that action will have. If a machine motion will occur, be sure that motion can take place without causing injury or damage.

15. Never leave a machine in an unsafe condition.

SAFETY INSTRUCTIONS FOR THE
OPERATOR PERSONNEL

Guidelines for Operator Personnel

1. Know and obey all general safety rules currently in effect in your plant. Follow instructions. If you are unsure or not clear about a procedure, immediately ask your supervisor.

2. Follow safety rules for your job, as defined and explained by your supervisor. Wear protective clothing and equipment. Gloves and/or articles of loose clothing must be kept clear of moving rolls and material when the Tube Mill Line is running.

3. Keep hands out of machine and moving parts when the Tube Mill Line is in operation. Do not operate equipment with opened electrical enclosures. Note: For servicing only, and by a qualified electrician, can an electrical enclosure be opened with power on.

4. Do not attempt repairs or adjustments that you are not qualified and/or authorized to perform.

5. Do not try to clear an obstruction or jam up while equipment is in operation.

6. Do not clean the equipment while turned “on” and/or in operation.

7. Hands should be kept clear of all moving parts when the Tube Mill Line is running. If a roll adjustment is necessary while the Tube Mill Line is operating, it should be made with the utmost care to avoid contact with moving components or material.

8. Be alert to any unsafe conditions or practices in your work area. Report any unsafe conditions, practices or actions by other personnel to your supervisor.

9. Be observant for unusual noises, oil leaks, water leaks, air leaks or other abnormal situations, and if they exist, report them to your supervisor.

10. Take proper steps to protect hands and bodies from material during the thread up operation.

11. Check the operation of the tube mill system in the manual mode, before placing equipment in the automatic or continuous mode.

12. Be certain all safety guards and devices are in place and are in good condition before starting work. GUARDS ARE EFFECTIVE ONLY WHEN THEY ARE IN PLACE. Do not allow equipment to be tested, adjusted, or put into operation with a guard or other device removed, or otherwise defeated. Do not allow them to defeated or passed.

13. Observe “Lockout” procedures as defined in your company’s safety regulations.

14. Before taking any action, analyze what effect that action will have. If a machine motion will occur, be sure that motion can take place without causing injury or damage.

15. Never leave a machine in an unsafe condition.

SAFETY INSTRUCTIONS FOR THE
MAINTENANCE PERSONNEL

Guidelines for Maintenance Personnel

1. Know and obey all general safety rules currently in effect in your plant. Read the applicable instructions.

2. Follow safety rules for the tube mill and machine maintenance, as defined and outlined by your supervisor. Wear protective clothing and equipment.

3. Properly lock out the machine for adjustment and repair.
- Exceptions are noted in the specific adjustment procedures.
- Be aware and look out for the “other guy”.
- Use padlocks and safety lockout tags as required.
- Observe machine warning tags and instructions.

4. Never leave a machine in an unsafe condition.

5. Prevent accidents by an active planned program of frequent inspections and prompt preventive maintenance procedures.

6. Do not allow equipment to be put into production unless it is in good operating condition.

7. Do not troubleshoot, adjust, clean, repair, or un-jam a machine while it is running. These operations must be done only after the power to the machine has been disconnected and all mechanical motion or energy has been expanded.

8. Replace all guards and safety devices after maintenance work and before start-up or test. Do not allow them to be defeated or bypassed.

9. Do not allow equipment to be tested, adjusted, or put into operation with a guard or other safety device removed, or otherwise defeated.

10. Be observant for unusual noises, oil leaks, water leaks, air leaks, or other abnormal situations and if they exist, report them to your supervisor.

11. Hands should be kept clear of all moving parts when the Tube Mill Line is running. If a roll adjustment is necessary while the Tube Mill Line is operating, it should be made with the utmost care to avoid contact with moving components or material.

12. Do not try to clear an obstruction or jam up while equipment is in operation.

13. Do not clean the equipment while turned “on” and/or in operation.

14. No electrical enclosure should be opened at anytime while the supply power is turned on, except by a qualified electrician when servicing is required.

15. Shut off main power supply to all components when equipment is not in use to prevent unauthorized use.

16. Inspect the entire Tube Mill Line after each maintenance. Make sure all maintenance and setup tools have been removed from the work area.

17. After maintenance, check the operation of the Tube Mill System in the manual mode before placing equipment in the automatic or continuous mode.

18. Be alert to any unsafe conditions or practices in your work area. Report any unsafe conditions, practices or actions by other personnel to your supervisor.

19. Follow “LIVE WORK PROCEDURES” as defined in your company’s safety regulations when air, pump, or electrical power must be “ON” for adjustment or repair.

20. Follow troubleshooting and repair procedures as written.

21. Before taking any action, analyze what effect that action will have. If a machine motion will occur, be sure that motion can take place without causing injury or damage. Get help to lift heavy loads.

22. Maintain your tools in a safe condition, and always use them properly. Do not use a hand tool or equipment that is damaged. If an electrical cord and/or device is damaged disconnect power and notify your supervisor.

23. Do not operate a forklift and other mobile equipment near the tube mill line or any tube mill controls unless you have been trained and/or been given permission by your supervisor.