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K-LINE INSULATORS SAFETY AUDIT

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Safety Assessment of the 300 Ton Press for compliance
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    ` PRE-START HEALTH AND SAFETY REVIEW REPORT 300 TON HYDRAULIC PRESS TWIN SLIDE -MODIFIED Page 1  of 31   ` PRE-START   HEALTH   AND   SAFETY REVIEW   REPORT   300 TON HYDRAULIC PRESS TWIN SLIDE -MODIFIED Report Prepared For: K-Line Insulators Tony Carreira P.Eng , President K-Line Insulators K-Line Insulators 50 Passmore Avenue, Toronto, ON, M1V 4T1 Review date: August 28, 29, 2019 Report date September 13, 2019 Prepared by Julian Kalac, B.Eng, P,Eng License Number: 90505462 NOTE: REQUIRES TESTING PRIOR TO FINAL ACCEPTANCE    ` PRE-START HEALTH AND SAFETY REVIEW REPORT 300 TON HYDRAULIC PRESS TWIN SLIDE -MODIFIED Page 2  of 31   PURPOSE OF THE PRE-START HEALTH AND SAFETY REVIEW (PSHR) The purpose of this pre-start health and safety review (PSHR) report is to assess previous modifications made to the press, identify deficiencies, recommend remedial measures to control or remove these potential hazards to ensure safety of the workers and full compliance with Occupational Health Safety Act OHSA Industrial Establishments 851. EMPLOYER K-line insulators (employer) is a manufacturer of silicone rubber high voltage insulators. Product lines manufactured by K-LINE INSULATORS include transmission and distribution suspension/deadend, line post and station post insulators. The manufacturing plant is located in Scarborough REVIEWER The reviewer is a licensed professional engineer, employed by the employer. DOCUMENTS REVIEWED The only documents available were hydraulic control circuit and mechanical drawing. No documentation regarding the modifications was provided nor electrical drawings Equipment Condition: The equipment reviewed was powered and operational. EQUIPMENT UNDER REVIEW:   AS OF AUGUST 30 2019. The equipment reviewed is the modified Macrodyne 300T Hydraulic Press, serial number 9895-MP-300DS, made in 1998 modified in 2006 and 2013 STANDARDS FOR EVALUATION: •   Safeguarding Machinery CSA Z432-16 •   Code for power press operation Health, safety, and safeguarding CSA Z142-10. •   Risk assessment method of CAN/CSA Z434-14. •   NFPA 79-2007 Electrical Standard F or Industrial Machinery, 2007 Edition •   CAN/CSA-Z460.section 19.62 control of hazardous energy •   Occupational Health and Safety Act, as amended by O.Reg. 528/00. •   Industrial Establishment OHSA Reg 851    ` PRE-START HEALTH AND SAFETY REVIEW REPORT 300 TON HYDRAULIC PRESS TWIN SLIDE -MODIFIED Page 3  of 31   IMPLEMENTATION Implementing the measures noted herein or by applying "Equivalency", (O.Reg. 851 S.2), will ensure compliance with O.Reg. 851 S.12, 24-27, 40, 75, 76 minimum, and ultimately S.7 " Pre-Start Health & Safety Review". Note: A number of the recommendations made herein deal with the modification / upgrade of existing protective elements (i.e. light curtains ,interlock switches, safety device(s), guarding, etc.), that forms a safety related system . Their addition / modification, etc., constitutes a "modified measure and I or engineering control" made under the Pre-Start Health & Safety Legislation (O.Reg 851 S7 (2)). Hence , once those safety devices / guards are added / modified / integrated, an additional Pre-Start Health & Safety Review (satisfying O.Reg. 85 I S.7), will be required. This is to verify the design, circuit reliability, modification, installation and operation of the new safety devices / system / guarding maintain(s) compliance with current Canadian Standards and applicable Ontario Occupational Health & Safety Law   Modified Press 2006 and 2013 1998 Original Press    ` PRE-START HEALTH AND SAFETY REVIEW REPORT 300 TON HYDRAULIC PRESS TWIN SLIDE -MODIFIED Page 4  of 31   SECTION 7 TABLE OF PSHR NOT LISTED IN TABLE 2 There are two (2) systemic CSA non-compliances in the plant that that are included are included in this review: 1. Estops —   does not stop the air cylinder, 2. No Lock out Tag out  being done during die changes OPERATION OF THE PRESS AND MODIFICATIONS The press is designed as a hydraulic twin slide press, with a positive displacement variable speed pump that drives 2 main hydraulic cylinders each one 12 ” in diameter , 12” stroke. Each cylinder is connected to a Ram (slide) which has a 150 Ton capacity and can run independently. Original press came with a standalone control console which was safe distance away Press was modified clamping cylinder were added press safety control was removed and replaced with 2 push to run buttons which are located in the danger zone at the bolster. The press stops when the push to run buttons are released or when it completes the full cycle returns    ` PRE-START HEALTH AND SAFETY REVIEW REPORT 300 TON HYDRAULIC PRESS TWIN SLIDE -MODIFIED Page 5  of 31  to the srcinal position. The maximum press speed in the downward stroke is 70 inches/min (1.16 inches /sec) and fast return speed of 90 inches/min (1.5 inches/sec). SUMMARY OF THE COMPLIANCE ISSUES 1. Point of operation not guarded FRONT OF PRESS HAZARDS The press is not guarded from any side the front back or side. The shield that was installed in the back is not secured and is often removed. Press has no safeguards, 2 hand push to run buttons are not guards . There are only 2 ways to guard this press that would be feasible. Option 1 preferred option. Recommendation 2 options LIGHT CURTAIN FRONT FIXED GUARDING 3 SIDES---SAFE DISTANCE = 12.8 INCHES The stopping time of the press including delayed push button response and operator initiation time was 1 second. The push buttons are spring loaded and have delayed response of 0.8to 1.2 seconds , The operator reaction time is 0.2 seconds The press travels at a controlled speed max of 1.5 ”  /second ttravel distance = 4 -8 inches .. At 0.25” slows down to max approach speed of 0.4 inches /second. RECOMMENDATION Install light curtains on the front of the press at a distance of 12.8 inches from  the bolster and fixed guards on the rear and side. The fixed guards shall be in compliance with the maximum opening for guards CSA z142 . The light curtain installation shall meet the following criteria: a) be installed 12.8 inches from the bolster  and b) Dual channel interlocked with E-stop and ram blocks c) Monitor the braking time of each cycle not to exceed 250ms or increase the light curtain distance based on the chart in Appendix d) a single fault in any part does not lead to loss of the safety function ; e) a single fault is detected at the time of failure. If such detection is not practicable, the fault shall be detected at the next demand upon the safety function; f) when a single fault occurs, the safety function is always performed and a safe state is maintained until the fault is corrected; and g) all reasonably foreseeable faults are detected. be interfaced with the control system such that the detection of an intrusion will stop the hazardous motion;
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