Rotating Equipment Safety

Working Safely and in a correct manner

Introduction
A 600-m3/h centrifugal steam condensate pump catastrophically exploded, following a major steam system upset. Before this incident there was a plant-wide power upset. As a precaution to prevent backflow through the de-energized pump, employees manually closed the suction and discharge valves. When the power was restored, the pump ran completely isolated. When the pump dramatically blew apart, the associated large piping was grossly twisted and the rotor was forced out of the electric motor. A five-pound piece of pump casing was found over 400 feet from the condensate pumping station. The accompanying photo displays the explosive force that blew the motors rotor out of the 75-hp electric motor casing. The investigating team established that this incident was the result of a pump being operated with the suction and discharge valves closed.

List of Equipments
Sulphona Formulation Dryer tion
Centrifugal Pumps Centrifugal Blowers Lobe Pumps Liquid ring Vacuum Pumps Roots Blowers Air Compressors Thin Film Dryers Agitators, Agitator assembly Rotary Valves Needler Screw Conveyor Belt conveyor Sieving Machine Granulator Band coolers

Ethoxylation

F2

Soap

ETP

WTP

List of Equipments
Sulphonation Formulation Dryer
Bagging Machine Pallet Truck Weighing Balance

Ethoxylation

F2

Soap

ETP

WTP

Sewing Machine
Flaker Metal Detector Reciprocating pumps Thermopac Pressure Vessels Cooling Towers Neutralizer Trident Air Dryer High Shear Mixer VFD
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List of Equipments
Sulphonation Formulation Dryer
Steam Traps Steam PCV Finned Tube HE Plate HE

Ethoxylation

F2

Soap

ETP

WTP

Cyclone separators
Cooling Tower ESP Packed Column Ozonator UV system Ion Exchange Column RVD Nauta

Safety of Maintenance Personnel

Maintenance personnel should be aware of potential hazards to reduce the risk of accidents

Safety Apparel
Insulated work gloves when handling hot bearings or using bearing heater. Heavy work gloves when handling parts with sharp edges, especially impellers Safety glasses (with side shields) for eye protection, especially in machine shop areas. Steel-toed shoes for foot protection when handling pants, heavy tools, etc. Other personal protective equipment to protect against hazardous/toxic fluids.

Pumps Safety
Couplings Guards:
Never operate pump without a coupling guard properly installed.

Flanged Connections:
Never force piping to make a connection with a pump. Use only fasteners of the proper size and material. Ensure there are no missing fasteners. Beware of corroded or loose fasteners.

Operation:
Do not operate below minimum rated flow, or with suction/discharge valves closed. Do not open vent or drain valves, or remove plugs while system is pressurized.

Pumps contd..
Maintenance Safety:
Always lockout power. Ensure pump is isolated from system and pressure is relieved before disassembling pump, removing plugs, or disconnecting piping. Use proper lifting and supporting equipment to prevent serious injury. Observe proper decontamination procedures. Know and follow company safety regulations. Never apply heat to remove impeller. Observe all cautions and warnings highlighted in pump instruction manual.

Lobe Pump Safety

Personnel Safety
Never touch the pump or the pipelines when pumping hot liquids or when sterilising.

Never stand on the pump or pipelines.

Never run the pump with both the suction side and the pressure side blocked. Never put your hands or fingers inside the port connections or anywhere close to rotating shafts. Do not start the pump unless the seal flush has been installed & is turned ON. Do not install clean service or repair pump unless all power is OFF & LOCKED OUT.

Equipment Safety

Be sure pumping head is clean & free of foreign material before rotating the shaft.
Do not close valves in inlet or discharge lines. Use thermal expansion joints to minimize forces on pump caused thermal expansion of piping.

Use flexible joints to limit transmission of mechanical vibration.

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Lobe Pump Safety

Equipment Safety
Do not keep operating pump without flush, which will damage seal & pump parts due to excess heat from dry running. Use cool, filtered flush media to obtain maximum service life of Seal components & use hot media for sticky material or which solidifies room temperature Do not put hands or fingers into pump body ports or drive area at any time during operation. Check direction of pump & drive rotation to ensure pump will rotate in proper direction. Ensure pump & drive are lubricated Drain product from pump prior to disconnecting the pump. Increase pump speed, use foot valve to improve priming. Install check valve in discharge line to prevent backflow of air or fluid.

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Centrifugal Blower
Personnel Safety
Do not touch the rotating parts when the fan is in operation. This may cause injury. Rotating parts such as couplings, pulleys, external fans, and unused shaft extensions should be permanently guarded against accidental contact with hands or clothing. Keep all tools, lose clothing and hands away from rotating or moving parts while the unit is running. Never run the blower unit without the belt guard installed. Do not touch the motor during operation or immediately after stopping. The surface is hot and may cause a burn. Do not use the product in explosive or corrosive environments, in the presence of flammable gases, locations subjected to splashing water, or near combustibles. Doing so may result in fire, electric shock or injury. Install the fan in an enclosure in order to prevent electric shock or injury. Disconnect the electrical power at the motor starter, fuse box or circuit breaker before working on the system. Take special precautions to make sure the power cannot be turned on while you are working on the blower. Use an approved Lock Out/Tag Out system. Make sure the motor is electrically grounded, the mounting bolts are properly secured, and all guards are in place before start-up. Wear safety glasses and earplugs when working on the blower. Do not operate blower/motor assembly with the belt guard or coupling guard removed. Make sure to install the piping to blower inlet, before starting the blower/motor.
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Centrifugal Blower
Equipment Safety
Do not operate blower with the outlet open to atmosphere. Connect system piping or butterfly valve to prevent overloading the motor. Check the final installation for proper amp loads. Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective devices to reduce harmful effects to your hearing. Do not use the fan beyond its specification, or electric shock, injury or damage to equipment may result. Keep the area around the fan free of combustible materials in order to prevent fire or a burn. To prevent the risk of damage to equipment, leave nothing around the fan that would obstruct ventilation. When an abnormality is noted, stop the operation immediately, or fire, electric shock or injury may occur. The motors surface temperature may exceed 70C, even under normal operating conditions. These temperatures can cause discomfort or injury to personnel accidentally coming into contact with hot surfaces. When installing, protection should be provided to protect against accidental contact with hot surfaces to prevent bodily injury.

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Coupling Guards

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Liquid ring vacuum pump

Maintain the correct inlet fluid pressure (0.5 to 1.0 Bar) for the better performance of the machine. Do not keep ends open. Close it properly with plugs & caps to protect the machine from moisture. Ensure impeller is turning freely with hand Do not keep the suction & discharge & the water piping dirty. Clean it

properly.
Give proper support to all piping to prevent any unwanted stress. Do not use hard water as a sealing liquid. Use soft water to avoid scaling inside the pipings

Ensure the bearings are supplied with correct grade of grease.

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Liquid ring vacuum pump

Inspect the motor & ensure the correct direction of rotation. If not isolate the power & interchange any two wires. Ensure that 2 valves are present at water inlet side. One is shut off valve to start or stop the machine & another one is regulating valve to control the quantity of fluid into the machine. Always open these valves. Do not run machine in the overloaded condition. Always check the current. Check for excessive tightening of the gland packing. Do not keep sealing fluid pressure in excess. If the pump rattles at high vacuum, slightly open the vent cocks. Check sealing liquid temperature. Excessive temperature may result in less suction as well as vacuum.

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Personnel Safety Mount a protective shield or screen, or the optional Finger Guard to the axial Fan installation site. Do not use the Box Fan with the Finger Guard removed. When performing any action that requires touching the blades, such as inspections, ensure that power is turned OFF. Unexpected operation of the Fan after, for example, the Fan has stopped due to contact failure or due to the operation of the overheating protection function (thermal protection), may result in injury. Do not hold the Fan by its power lines, or pull the power lines with excessive force. Doing so may cause damage to the wire insulation or break the wire, resulting in injury due to electric shock or the Fan falling. Equipment Safety Be sure to secure the Fan with the mounting bolts. Not doing so may result in injury due to the Fan falling. Do not use the Fan outside the rated temperature range or above the rated voltage. Doing so will cause the temperature of the coil (at the center of the Fan) to increase, and may result in deformation or burning of the blades. Provide measures, such as circuit-breaker fuses, on the power supply lines of devices that are using Axial-flow Fans. Short-circuiting of the Fan may adversely affect other devices. Do not use the Fan in locations subject to flammable or explosive gases. Do not attempt to disassemble, repair, or modify the Fan. A precision-type ball bearing is used to hold the shaft of the Fan. Ensure that the Fan is not subjected to shock, such as falling, otherwise the service life and performance characteristics of the Fan will be adversely affected. Do not wire the power lines of the Fan in series with those of other Fans or devices. Doing so may cause a voltage above the Fan's rated voltage to be applied, and this may result in malfunction or burning. Be sure to wire devices in parallel.

Axial Flow Fans

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Roots Blowers
Personnel Safety
Keep fingers and clothing away from blower inlet and discharge ports, revolving belts, pulleys, drive coupling etc. Do not use the air discharge from this unit for breathing not suitable for human consumption. Do not loosen or remove the oil filter plug, drain plugs, covers or break any connections, etc., in the blower air or oil system until the unit is shut down and the air pressure has been relieved. Electric shock can and may be fatal. Open main, disconnect switch, tag and lockout before working on the control. Disconnect the Blower unit from its power source, tag and lockout before working on the unit. Stop the unit if any repairs or adjustments on or around the Blower are required.

Equipment Safety

Do not operate unit if safety devices are not operating properly. Check periodically. Avoid bypassing safety devices. No attempt should ever be made to control the capacity of compressor by means of throttle valves in the intake or discharge piping. This increases the power load on the motor and may seriously damage the compressor.

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Roots Blowers
Equipment Safety
Over tightened belts leads to heavy bearing loads and shaft deflections and may result in premature failure of bearings / shafts. Piping should be supported near the compressor to eliminate dead weight strains on the blower. A flexible pipe bellow is recommended in the discharge pipeline, close to the compressor discharge, so as to isolate compressor and pipeline vibrations. Choking of suction filter leads to increased load on the blower. Replace filter every three months. Servicing the air filters is one of the most important maintenance operations to be performed periodically to ensure long blower life. Relief valves should be placed as close as possible to the Blower discharge. They are not meant to discharge full capacity and therefore cannot be taken as safeguard against total blockage. Ensure lubrication of bearings and gears is regularly maintained. This avoids premature failure of Blower. Provide suitable protection/cover to prevent lubricant getting contaminated by dust, dirt and water as these render it ineffective.

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Pump Case study -1

In an abandoned unit, a pump that handled a 50% solution of caustic soda was isolated by closing both valves.

A contractor was asked to switch on a ventilation fan for the nearby area. The switch for the fan was close to that for the pump and the labels were small
The contractor switched on the caustic pump in error.

The pump ran between closed valves and overheated. There was a loud boom, which rattled windows 60 m away. The pump was damaged and dislodged from its base plate.

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Pump Case study -Discussion

The incident would not have occurred if

The pump had been drained. The pump had been defused The switches were near the equipment they served. (Emergency switches can be away) The labels were easy to read Someone familiar with the unit was asked to start the distillation fan

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Can this happen at Galaxy?

A reciprocating compressor was started up in error with the delivery valve closed. The relief valve was too small and the packing round the cylinder rod was blown out.

The relief valve in this case was merely a sentinel (safeguard) to warn the operator and was not capable of passing the full out put of the compressor
A reciprocating pump was ordered that was capable of delivering 2 m3/h. The

manufacturer supplied his nearest standard size, which was capable of delivering
3 m3/h, but sized a relief valve for 2 m3/h.

When the pump was operated against a restricted delivery, the coupling rod was bent. Fortunately , it was the weakest part of the system.
A relief valve, supplied with a compressor , was of an unsuitable type, and was
mounted horizontally and vibrated so much that the springs dented the casing.

Relief valves should be mounted vertically so that any condensation or dirt collects in them has the maximum chance of falling out.
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Rotary Valve
Personnel Safety
Do not attempt to work on, clean or service an airlock, or open or remove any protective cover, guard, grate or maintenance panel until the POWER has been turned off and LOCKED OUT, and the valve has come to a complete stop. Never place hands or fingers in an airlock, unless it has been disconnected and locked out, and a wooden block has been placed in the valve to prevent the rotor from turning. Do not manually override or electrically bypass any protective device. Do not connect power to or operate an valve unless all moving parts are covered and all covers, guards, grates, and maintenance panels are in place and securely fastened. Do not attempt to start an valve when loaded. Never place any part of your body under or near rotating members or moving parts of an airlock. Rotating members and moving parts must be completely enclosed before connecting power and before operation. Keep away from an valve when it is running.

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Rotary Valve
Personnel Safety
Use personal protective equipment when and where appropriate, such as hard hats, helmets, gloves, earplugs, and eye protection devices. Keep personal protective equipment in good repair and convenient to the operator. High voltage and rotating parts can cause serious or fatal injury. Only qualified, trained, and experienced personnel should perform installation, operation and maintenance of electrical machinery. Make sure that the motor and the frame of each valve is effectively grounded in accordance with OSHA safety and health standards, the National Electrical Code and local codes. All protective covers, guards, grates, maintenance panels, switches and warning decals must be kept in place and in good repair. Any valve with a damaged, malfunctioning, defective, or missing protective device must be taken out of service until the protective device can be repaired or replaced. All valve inlet and discharge openings must be completely enclosed to prevent human access when valve is operating, and must remain enclosed until POWER IS TURNED OFF AND LOCKED OUT.
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Rotary Valve
Equipment Safety
A valve must be equipped with a properly functioning Protective Interlocking Electrical Control Switch (PCS), a Padlockable Manual Power Lockout Switch, and with the other basic safety equipment listed above. On-off, interlock and padlock functions of the PCS must be tested and logged daily by supervisory personnel. Keep the workplace cleaned up and free of dirt and dust at all times. Do not attempt to work on slippery or unsafe ladders or work platforms when maintenance or repair work is being performed on an airlock. Do not climb on ladders or work on platforms unless maximum load rating is posted. Do not exceed maximum load ratings when installing or servicing an airlock. Never allow any kind of metal or other foreign objects to enter an airlock.

Any valve that is used in the processing of explosive materials in hazardous environments requires an evaluation on the part of the user and operator of proper and adequate valve monitoring equipment, dust control, explosion relief venting, and electrical equipment enclosures.

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Thin Film Dryer

Personnel Safety
Do not allow person to operate the machine unless they have carefully read and understood the operating procedure of equipment.

Never insert body parts or foreign objects into the running machine. Keep fingers Hands, Feets, Tools, Rods, Sticks or any other foreign parts away from moving parts while machine is running condition.
Do not touch rotating parts when machine is in running condition, this may cause injury. Rotating parts such as coupling pulley, belt should be permanently guarded against accident contact with hand or clothes. Do not touch the motor during operation or immediately after stopping. The surface is hot and may cause a burn. Take precaution to remove the fuse during maintenance work in machine.

Equipment Safety

Make sure the motor is properly earthed. Make sure that the direction of the dryer blade it must be clockwise when see at the top of dryer. After shut down first check the motor rotation it must be clockwise when see at the top.

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Thin Film Dryer

Equipment Safety
Make sure dryer current is within limit. No load current = 60-80 Amp, On load current = 100-130 Amp. When dryer current is high automatically in running condition immediately inform to maintenance person -it may be cause of blades detached from the ring. Make sure that the Gear box temperature is on limit (60-90c) otherwise due to high temperature gear box will be damage. Keep the area around the machine free of combustibles material in order of prevent fire or burn. When abnormality is noted (high vibration, high sound) stop the machine immediately otherwise electric shock, fire, injury may occur. Make sure the bush cooling water supply is proper (20 drops/ min) otherwise the temp of bush is high & due to friction possibility of fire is there.

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Granulator
Personnel Safety
Never insert body parts or foreign objects into the running machine. Keep fingers, hands, arms, feet, tools, rods, sticks or any other foreign objects clear of moving parts when running the machine. Make sure the motor is electrically grounded, the mounting bolts are properly secured and all guards are in place before start up. Disconnect machine and lock out power before opening, adjusting, cleaning, servicing and changing screens, impellers, guards or any other parts. Appropriate care must be taken when handling perforated screens which have holes that break out on edges of the screen flange. Wear proper apparel. Do not wear loose clothing, gloves, neckties, rings, bracelets or other jewelry which may get caught in the machine. Always use safety glasses when operating the machine. Use mask if operation is dusty.

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Granulator
Equipment Safety
Check the direction of rotation of impeller it must be clockwise direction when viewed from above the machine.

Do not start machine under load. Or empty condition.

Stop machine immediately if the impeller is heard rubbing or ticking. At the time of tripping call electrician for resetting the granulator. Do not allow high moisture in feed so as to avoid tripping. Keep the area around granulator free of combustible material in order to prevent fire or burn. Before trying operation with different screen and impeller combinations check the Gap adjustment between impeller and screen. Inspect interlock switches and cables regularly. Replace if damaged or defective. Ensure that interlock switches are working correctly prior to using the machine. Do not disable any interlock switch.

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Needler
Personnel Safety
Do not touch rotating parts when needler is in running condition, this may cause injury. Rotating part such as coupling guard, pulley belt should be guarded against accident contact with hand or clothes. Keep all tools, loose clothing and hand away from rotating part. Check the direction of motor it must be in clockwise direction. Check the direction of needler plodder while looking at it from the extrusion end. The Right side worm must rotate in anticlockwise direction and the Left side worm must rotate in clockwise direction. Ensure the air supply is on, starts motor of needler after making sure that the clutch is disengaged switch on the clutch and operate the needler through push button provided on the operation console. Ensure that mass feed to the needler is free from any extraneous/ hard material. Never allow foreign material except SLS powder as it will damage barrel and warm. Ensure that the temperature of extrusion plate is not exceeding 70C. Do not circulate the water initially in needler jacket. Once the SLS powder has reached the barrel, water should be started now. Regulate the flow of water through the barrels by operating the relevant valve on the inlet and maintain uniform water supply. At the time of needler stoppage water supply should be closed condition.
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Equipment Safety

Needler
At the time of die plate chock up take dryer material outside of needler, stop needler, remove entire material from hopper, fix new die plate, take approximate 25 Kg material in hopper and then start the needler. If dryer is stopped more then half hour change the die plate of needler.

After every 4000 hours of operation of the needler change the oil in main gear box and bearing housing.
After every 200 hours, lubricate the drive shaft by injecting grease in to the grease nipple provided on bearing housing. Ensure that the transmission belts (V belt) are correctly stretched. If necessary adjust the tension using relevant stretcher. When abnormality is noted (abnormal sound, high vibration) stop the machine immediately otherwise electric shock, fire, injury may occur. Keep the area around the machine free of combustibles material in order of prevent fire or burn. Make sure needler current within limit. No load current = 25 Amp, on load current = 30-45 Amp. If needler current is continuous increases in running condition, stop needler, remove entire material from hopper, fix the die plate then start the needler.

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Mixers and Agitators

Equipment Safety
Rotate mixer shaft by hand to check shaft straightness and assure that the impeller is free of any obstructions in the tank. The impeller rotates in the direction shown in the assembly drawing. Opposite rotation may cause overload and inefficient mixing. Vortexing may occur if liquid level is too close to the upper impeller. This will cause aeration of the product and excessive vibration of the equipment. When mixing products of dissimilar viscosities and/or specific gravities the lighter or less viscous material should be introduced first. Gradually add the heavier material or powders into the center of the tank while the agitator is running. Never dump large amounts of powder or solids into the mixing tank. This may create clotting or sanding in of impeller and cause damage to the equipment. Do not start mixer with impeller buried in solids or with liquid solution solidified. Damage will occur. If impeller is buried in solids prior to starting mixer, solids must be dispersed. This may be achieved with an air hose, a recirculating pump, or a large stirring stick if necessary (depending on tank size).

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Mixers and Agitators

Equipment Safety
Check gearbox lubrication level. Some models may be shipped "dry" (without lubricant) and must be filled with the proper lubricant before startup. Check the oil level before start up. Verify that none was lost during shipment/installation. Do not over or under fill the gearbox. Shaft seal must be lubricated/flushed during operation of mixer. Extended operation of mixer when liquid level is at or near bottom impeller is not recommended. Excessive loading and vibration will occur. Keep motors free from oil, dust, dirt, water, and chemicals. Keep air intakes and outlets free from foreign material. Always lockout power before installing or removing mixer equipment High voltage and rotating parts can cause serious or fatal injury. Electric machinery can be hazardous. Installation, operation, and maintenance of electric machinery should be performed by qualified personnel.

Personnel Safety

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Safety Measure Strategy

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Machinery Hazard Prevention

Spatial separation between human and machine work spaces

Isolation principle: Safety protection like guards

Temporal separation
Stoppage principle: Safety protection like interlocking devices

Human Workspace

HAZARD ZONE

Machine Workspace

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