FIRE SAFETY PRACTICES FOR FACILITIES PREAMBLE state andfederallaws andregulations. be certainthatitsoperations complywithrelevant local, advice. Eachcompanyshouldconsult itsowncounselto conform to.Thisdocumentisnotintended tobelegal as appropriate regarding regulations theyare required to consult withtheirlocal,state,and/orfederal authorities recycling process. ISRIencouragesalltire recyclers to procedures associated withthatparticularphaseofthe and makessuggestionsregarding proper practicesand looks ateachphaseofatypicaltire recycling facility determine whichsectionsapplytothem.Thedocument should review thisdocumentinitsentirety inorder to design, layout,operationandtarget markets.Readers scrap facilityaseachisuniqueinits Not everysectionofthisdocumentwillapplyto and hasdevelopedthisdocumenttohelpthemdoso. encourages tire recyclers tooperatetheirfacilitiessafely The InstituteofScrapRecyclingIndustries(ISRI) PREAMBLE DEFINITIONS ADDITIONAL REFERENCES

“Arcing” is defined as a luminous discharge of electric current that ISRI Resources is formed when a strong current jumps a gap in a circuit or between ¤¤ Safety Manual – http://www.isrisafety.org/assets/files/ two electrodes. ISRISafetyManual-BOARD%20APPROVED%2010-09.pdf.

“Chip” is defined as tire material that has been processed to a NFPA uniform size, shape and consistency that generally ranges between ¤¤ NFPA 1, 2006 Edition, Chapter 33 – Storage of Outside ; 1 and 5 inches in any two dimensions. ¤¤ NFPA 654, 2006 Edition, Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids; “Fines” are defined as materials that pass a 4.75mm sieve; these ¤¤ NFPA 68, 2007 Edition. materials may include rubber, fiber, inorganic and organic matter, dirt, and other non tire materials. OSHA ¤¤ 29 CFR 1910.38; “Finished Product” is defined as any non whole tire material ¤¤ 29 CFR 1910.106; that has been sized and classified as a specification grade feedstock ¤¤ 29 CFR 1910. 137; material that is used for the manufacture of other goods. ¤¤ 29 CFR 1910.146; ¤¤ 29 CFR 1910.147; “Inspection” is defined as a detailed and documented analysis of ¤¤ 29 CFR 1910.156; all operating components of the shredder and feedstock material. ¤¤ 29 CFR 1910.158 to 29 CFR 1910.160; In addition to those that are conducted during routine maintenance ¤¤ 29 CFR 1910.163; operations, inspections must be conducted whenever monitoring ¤¤ 29 CFR 1910.164; activities reveal abnormalities. Inspections should be performed in ¤¤ 29 CFR 1910.252; strict adherence to all safety policies and procedures, with particular ¤¤ 29 CFR 1910.301; emphasis paid to the control of hazardous energy. ¤¤ 29 CFR 1910.305; ¤¤ 29 CFR 1910.307; ”Monitor” is defined as observing the operation and condition ¤¤ 29 CFR 1910.308; of the equipment and components needed to operate the shredder. ¤¤ 29 CFR 1910.331 to 29 CFR 1910.335; It also means observing the feedstock material from a safe distance ¤¤ 29 CFR 1910.399. to prevent a hazardous situation from developing. This type of observation must be routine and ongoing while the shredder is operating.

“Raw Material” is defined as tire derived material that is shredded to 4” or larger.

“Rough Shred” is defined as a tire that has gone through a shredding process once with no further reduction in size.

“Whole Tire” is defined as a tire that has not been reduced in size. This includes but is not limited to tires that contain rims. PREAMBLE VISITORS or toothers. facility toensure theydonotposeahazard tothemselves It isimportanttoknowthelocationofallvisitors CONTROLVISITOR GUIDELINES

The perimeter of the facility should be controlled by use of fencing, motion detectors, alarm systems, security guards or onsite personnel to minimize the possibility of unauthorized personnel gaining access.

A proper visitor control protocol should be put in place to ensure the identity and location of all visitors at all times.

Visitors should be issued temporary identity cards/easily identifiable hard hats, jackets, etc.

Visitors to the facility should be required to sign in at the office and be informed as to proper safety precautions to use while on the premises, i.e. no smoking or use of open flame.

In lieu of a manned checkpoint, direct all visitors to a safe and secure location for check in. VISITORS EMERGENCY EMERGENCY RESPONSE EMERGENCY local regulations. and state tothefacilityasrequiredby related important information descriptions, layouts, etc., ofequipment, material, andother schematics, have agencies Ensure localemergencymanagement EXTERNAL COMPONENTSOFEMERGENCYACTIONPLAN and location. isspecifictothefacility’sPlan that layout, equipment, processes Each facilityshoulddevelopandkeeponfileanEmergency Action INTERNAL COMPONENTSOFEMERGENCYACTIONPLAN responsible parties. to items shouldbedocumentedandavailable All oftheabove response personnel. basis and, totheextentpossible, withlocalfire coordinated An emergencyresponsedrillshouldbeconductedonaregular of firesuppressionequipment. manufacturer’s regardingperiodictesting recommendations operation. ordinancesand state/local Followallapplicable inspected andtestedonaperiodicbasistoensureproper fire extinguishers, pumps, supply water etc., shouldbe Fire suppressionequipment, suchassprinklersystems, should ornotdoduringanemergencyevent. they employeesbetrainedtounderstandwhat It isimportantthat during andafteranevent. persontospeakwiththemedia asthedesignated also serve arenotified. agencies and appropriate could Thecoordinator an incident, toensureallemployeesareaccountedfor responseduring theappropriate tocoordinate Coordinator anEmergencyResponse A facilityownershoulddesignate

STORAGE

Scrap tire processing introduces several potentially significant fire hazards. These hazards may exist during all phases of storage, processing and transportation. History has proven that once a pile of rubber products reaches a certain internal temperature, it becomes progressively more difficult to cool it. Once the threshold temperature is reached, runaway heating begins and a fire becomes likely, if not inevitable. Once a pile ignites, the fire can grow dramatically, with tremendous speed and with potentially devastating results. A critical component of fire prevention involves emergency preparedness. Procedures should be implemented that incorporate adequate space between piles to ensure a fire in one pile cannot propagate to adjacent piles. Similarly, adequate space should be maintained between piles and operating facilities to minimize any life hazard in the event a fire occurs.

As state and local fire codes and other statutes may impact a facility’s layout and storage requirements, it is important to consult with your state and local regulatory bodies to ensure compliance. Additionally, consultation with the local fire department is also important. STORAGE STORAGE RECOMMENDATIONS FOREIGN MATERIAL IN STORAGE PILES Scrap tire piles should range between 2,500 to 5,000 square feet in size. Materials such as chemicals, oils, batteries, etc. should not be in or near piles.

All material should be spaced approximately 20 to 50 feet away from buildings, additional Manage the amount of fines present as appropriate. piles, equipment, property lines, etc. Separation and segregation techniques and procedures should be put in place to ensure Fire lanes or roads should be approximately 20 to 50 feet wide and maintained to provide foreign materials are filtered out before processing. sufficient access in the event of an emergency. ¤¤ If this distance cannot be met, a suitable alternative should be implemented to Employees should receive proper training on management of pile contents ensure all appropriate safety standards are met. and structure. Fire department personnel should have adequate access to water supplies. HEAVY EQUIPMENT Particular care should be given to removal of dust and oily residue buildup and inspection Fire suppression equipment such as hoses, on site fire trucks, water tankers, etc. should of components to reduce the potential of equipment starting a fire. be readily and easily accessible. Ensure that all equipment contains a fire extinguisher in good working condition. Consider the use of a water “wetting agent” or other additives to enhance the fire suppression capabilities of water for extinguishing fires in large storage areas. Equipment that contains or oils should have a mobile spill kit on board.

Precautions should be taken to prevent the radiant heat of a fire from igniting Weekly and monthly inspections should be recorded, with special note of items surrounding areas. that are defective or in need of repair. Any items that are repaired or replaced should Sufficient storage capacity should be available to provide for safe storage even during also be documented. max. production demands triggered by market fluctuations, delays in shipment, etc. An employee should not operate any piece of equipment until they have been trained in the Establish a “must move date” for all material based on size and composition to minimize proper and safe use of that equipment, including but not limited to, daily inspections and fire risk. maintenance, safe operation around equipment and other employees and the safe operation on a given site. Ensure all material is sized and stored in like groups, mixing of sizes can create monitoring and cleanliness issues. All training must be documented as required by your state and local agencies. All material should be stored in an area away from objects that can attract lighting. Heavy equipment should be stored a minimum of 50 feet away from material and other flammable substances, such as fuels, oils, chemicals, grass and weeds or other items Suggested storage methods include, but are not limited to: that might easily ignite or propagate a fire. ¤¤ Bulk Storage Piles–It is common practice to store finished products in rows prior to shipment. ACTS OF GOD ¤¤ Trailers–Storage of finished product in trailers prior to shipment should be managed Rubber products should be stored in a manner that reduces potential Acts of God, such appropriately. as employing lightning suppression protocols. ¤¤ Bins, Sacks or Totes–Although this method of storage may be considered the least threatening, hazards may still be present. Storage of material prior to shipment should RAW MATERIAL AND WHOLE TIRES be managed appropriately. Raw material piles containing shredded material should not be compacted. TEMPERATURE MONITORING FINISHED PRODUCT The internal temperature of all material should not exceed 120ºF at a depth of six feet. Clean, processed tire wire, if stored in a pile, should be stored in an area that has minimal exposure to lightning strikes. Piles of tire wire need to be kept at a lower height due to its The monitoring of the pile should be recorded on a regular basis and nature of acting as a lightning rod. properly documented. Tire wire will generate heat as it begins to oxidize. Monitoring should be done on this A rise in temperature in either the interior or exterior of the pile should be noted, material daily to ensure that there is not excessive heat buildup due to oxidation. especially in the context of variances in ambient temperature. Temperatures above 120ºF should be avoided. As material will generally produce heat from the interior to the exterior of a pile, internal temperature monitoring with a suitable device, i.e. a probe or other appropriate device, is desirable.

Suggested cooling strategies include pneumatic conveying, auguring, and agitating or stirring material periodically. SHREDDING should beexercised whilethemachineryisbeingutilized. shredder, potentially significanthazards exist andcare as common.Inoperatingeitheraprimary orsecondary of theoperation,andalthoughthisis acceptable, itisnot medium tohighspeedunitsare utilizedforthispart shaft/blade arrangements.Occasionally singleshaftor speed, hitorque machinesutilizingtwin,counterrotating secondary shredding isgenerallyaccomplishedusinglow produced bytheprimaryshredder. Bothprimaryand further shred andreduce theparticlesizeofmaterial a “chip”or“rough shred” whilesecondaryshredders Secondary. Primaryshredders reduce wholetires to There are twodifferent types ofshredders: Primary and SHREDDING SHREDDING Observe proper lockout/tagout procedurespriortoinspecting properlockout/tagout Observe SAFETY PRECAUTIONS is maintained to minimize heat buildupand dust. is maintainedtominimize heat pattern toensureproperflow andspray inspected periodically mistsystemisinstalled,If awater itshould bemonitoredand inspected andtestedregularly. theshreddingareashouldbe systemsfor Water supplies anddelivery WATER SUPPLIES ¤ ¤ ¤ drivenshredderheadsinspect; For electromechanicalorhydraulically Inspection ofDriveComponents duringprocessing. minimize frictioncreated to Blades shouldbeinspectedandre-torquedasappropriate adjustedcomponents. potential offirefromwornorimproperly Proper maintenanceoftheshredderheadisimportanttoreduce and appropriate. equipmentasnecessary or repairtheaffected afire.possible fuelsourcefor isobserved, Ifbuildupofmaterial clean due tofrictionorsparks. canbea accumulation Suchmaterial buildup intheseareastopreventexcessiveheat does notaccumulate material toensurethat throughouttheworkday monitored regularly mustbe The shreddercuttingchamberandbearingtemperatures in thearea. orcontaminants should besufficienttopreventbuildupofmaterial ashutdownperiodofextendedlength.before Housekeepingactivities and throughouttheworkday shredding areashouldbeperformed potential fuelloadsand/orfrictionelements. Regularcleaningofthe Good housekeepingintheshreddingareaisessentialtoreduce SHREDDER MAINTENANCE alltimesintheshreddingarea. Smoking shouldbeprohibitedat and handled. tobeoperated procedures ormaterials withthe hazardsassociated to ensureemployeesunderstandany shouldbeestablished A properemployeetrainingprogram and maintenanceprocedures. Refer tothemanufacturer’s properinstallation for recommendations maintenanceonthese items. any or performing ¤ ¤ ¤

wear; and Belts, clutches, gearboxesandother mechanicalcomponents. leaksandexcessive Hydraulic componentsfor components; looseordamaged Electrical connectionsfor

Refer to Appendix additionalinformation. A for the endofday. cutting,When possibleavoid welding, 2-4hoursbefore grinding dispersion ofsparks. Where applicable, dustcollectionequipmenttomitigate turnoff when maintenanceonequipmentisrequired. Should befollowed are performed. Required whenevertorching, operations welding or grinding HOT WORKPROGRAM buildupfromafailure. minimize potentialheat to properoperation Bearings shouldbeinspectedandmonitoredfor which couldcauseafire. builduporotherfailure withoutcausingexcessiveheat be operated andequipmentcan ensure propermaintenancehasbeenperformed Inspect drivecomponents, suchasbelts, clutchesandgearboxesto intheshreddingarea. maintenance ontheequipmentlocated any outprocedurespriortoperforming properlockout/tag Observe MECHANICAL MAINTENANCE asnecessary. shouldbeupdated diagrams All electricaloutletsshouldbemapped. andtechnical Suchmaps adviceand/orguidance. for engineer youconsultwithyourlocalelectricianorelectrical is advisedthat ElectricalCodeasapplicable. National Refer totheappropriate It repaired orreplacedasnecessary. Electrical connectionsshouldbecheckedonaregularbasisand anignitionsource. creating thereby Loose, uporarc, heat wornorbrokenelectricalcomponentsmay ELECTRICAL MAINTENANCE

SCREENING and managedinasimilarmanner. this equipmentwillbesimilarandshould bemonitored Regardless, thepotentialhazards associatedwith the appropriate equipmentforagivenoperation. products andthedesired sizegenerallydetermine and “rotex” typescreens. Thevolumeandqualityof used suchastrommels, discscreens, shakerscreens times. There are manydifferent typesofscreens and inmanyfacilitiesproducts are screened multiple Screening ofprocessed rubberiscommonpractice SCREENING

SCREENING due tofriction, apossibleignitionsource. creating thereby such asshaftsorbearings, builduporsparks whichcancauseheat aroundmovingparts, buildupofmaterial for inspected periodically componentsshouldbe Screening equipmentandassociated Smoking in the screening area should be prohibited at alltimes. Smoking inthescreeningareashouldbeprohibitedat andhandled. tobeoperated procedures andmaterials ofthe hazardousnature employees understandthepotentially toensure shouldbeestablished A properemployeetrainingprogram and maintenanceprocedures. Refer tothemanufacturer’s properinstallation for recommendations maintenance ontheseitems. any outprocedurespriortoperforming properlockout/tag Observe SAFETY PRECAUTIONS ¤ ¤ ¤ friction elements. screening areaisimportanttoreducepotentialfuelloadsand/or surrounding areas. Sufficientdustcontrolandhousekeepinginthe During processing, andfiberdustisreleasedintothe rubber SCREEN MAINTENANCE ¤ ¤ ¤ ¤ ¤

more recommendations. to minimize potential heat buildupfromafailure. to minimizepotentialheat properoperation Bearings shouldbeinspectedandmonitoredfor failure whichcouldcauseafire. builduporother withoutcausingexcessiveheat can beoperated andequipment to ensurepropermaintenancehasbeenperformed Inspect drivecomponents, suchasbelts, clutchesandgearboxes maintenanceontheseitems. any performing outprocedurespriortoinspectionor properlockout/tag Observe Refer totheDustControlsectionofthisdocumentfor

Refer to Appendix additionalinformation. A for theendofday.before cutting,When possibleavoid welding, 2-4hours grinding dispersion ofsparks. Where applicable, dustcollectionequipmenttomitigate turnoff also required. whenmaintenanceonequipmentis Should befollowed are performed. Required whenevertorching, operations weldingorgrinding HOT WORKPROGRAM asnecessary. shouldbeupdated diagrams All electricaloutletsshouldbemapped. andtechnical Suchmaps adviceand/orguidance. for engineer youconsultwithyourlocalelectricianorelectrical advised that ElectricalCodeasapplicable. National Refer toappropriate Itis or replacedasnecessary. Electrical connectionsmustbecheckedonaregularbasisandrepaired anignitionsource. creating uporarcthereby heat Loose, wornorbrokenelectricalcomponentsconnectionsmay ELECTRICAL MAINTENANCE

SEPARATION reduce theexposure ofafire hazard. storage anddisposalofthesematerials willsignificantly create apotentialfire hazard. Proper conveying,handling, sources suchassparks,staticelectricity&frictioncan up toassure optimalperformanceatalltimes.Ignition requires maintenance ofsystemsandequipmentbekept associated withprocessing andhandlingthesematerials detectors fornon-ferrous material.Thepotentialrisks magnets, althoughsomefacilitiesalsoincorporatemetal common methodofseparatingferrous materialistoutilize separation isanintegralpartoftire processing. Themost stream forreprocessing ordisposal.Formanyoperations, fiber orothercontaminantsare separatedfrom therubber During theseparationprocesses, materialssuchassteel, SEPARATION SEPARATION attached to the wire has the potential to be a source for afire. tothewirehaspotentialbeafuelsourcefor attached fiber, ifitisextractedfrompassengertires. especially Therubber and containasmall amountofrubber wirewillgenerally Separated Separated Wire ¤ ¤ ¤ ¤ Safety Precautions Magnets &MetalDetectors FERROUS/NON-FERROUS SEPARATION ¤ ¤ ¤ ¤ Mechanical Maintenance ¤ ¤ ¤ ¤ Electrical Maintenance ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

to minimize potential heat buildup fromafailure. to minimize potentialheat properoperation Bearings shouldbeinspected andmonitoredfor buildup orotherfailure whichcouldcauseafire. withoutcausing excessiveheat equipment canbeoperated and boxes toensureproper maintenancehasbeenperformed Inspect drivecomponents, suchasbelts, clutchesandgear electricalcomponentsandcausingsparks. the wirepenetrating buildupfromfrictionor components isessentialtopreventheat ofwireonthevarious Periodic cleaningtopreventaccumulation maintenance ontheseitems. any procedurespriortoperforming proper lockout/tagout Observe adviceand/orguidance. for engineer youconsult withyourlocalelectricianorelectrical advised that ElectricalCodeasapplicable. National Refer toappropriate Itis asnecessary. shouldbeupdated diagrams All electricaloutletsshouldbemapped. andtechnical Suchmaps repaired orreplacedasnecessary. Electrical connectionsmustbecheckedonaregularbasisand anignitionsource. creating uporarcthereby heat Loose, wornorbrokenelectricalconnections orcomponentsmay andbehandledappropriately.smoldering materials inspectedfor the areashouldbethoroughly “hotspots” orresidual After maintenanceisperformed, andpriortorestartingmachinery, reduce firepotential. priortomaintenance the areashouldbesoakedwithwater cannotberemovedorprotectedfromsparks,If thewirematerial donotcomeincontactwiththismaterial.and grinding present, sparksfromwelding careshouldbetakentoensurethat wireis maintenanceinanareawhereseparated When performing areashouldbeprohibited Smoking intheseparation andhandled. tobeoperated of theproceduresandmaterials hazardousnature ensure employeesunderstandthepotentially to shouldbeestablished A properemployeetrainingprogram andmaintenanceprocedures. installation Refer tothemanufacturer’s proper for recommendations outprocedurespriortoinspection properlockout/tag Observe or performing any maintenanceonthese items. any or performing at alltimes. at ­

FIBER ANDDUSTSEPARATION ¤ ¤ Hot Work Program ¤ electricity hasbeenobserved. equipment arefunctioningproperly. Noteinstanceswherestatic fire. into sparkorfiresuppressionsystemsincorporated Ensurethat leadto chargeand/orproducesparksthat astatic generate may explosive. airthroughpipes andequipment by Movingthismaterial control issues. Dustcanbehighlyflammable, andpossibly material. Duetoitslightweight, dustandfibercanposesignificant lighter, toberemovedfromthedenserproduct material undesirable allows involvesalarge airsourcethat usually or dustseparation activities. orgrinding granulating rubber perform that Fiberand/ part oftireprocessingplants isanintegral Fiber ordustseparation ¤ ¤ ¤ Electromagnets ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

before theendofday.before Should be followed whenmaintenanceonequipmentis Should befollowed Required whenevertorching, operations weldingorgrinding on fiberanddustcollection. moredetails Refer totheDustControlsectionofthismanualfor moreinformation. for on thispage &MetalsDetectors" under"Magnets See therecommendations wheninoperation. Monitor temperatures Safety Precautions Refer to Appendix additionalinformation. A for cutting,When possibleavoid welding, 2-4hours grinding dispersion ofsparks. dustcollectionequipmenttomitigate turnoff Where applicable also required. are performed.

GRANULATION or steelrollers canbeutilized. machinery suchasa“crackermill”,cryogenic freezing, be furtherreduced insize.Various typesofhigh-end in thematerial.Tertiary grindingrequires thematerialto friction andsparksthatare generatedfrom wire contained equipment. Fire hazards atthisstagecanbecausedby is usuallyaccomplishedwithmediumtohighrpmspeed also removed atthisstage.Secondstageprocessing 1 inchinsize.Significantamountsofwire andfiber are Material produced inthesecondstageissmallerthan Typically granulationisconsidered secondstageprocessing. GRANULATION GRANULATION ¤ ¤ ¤ Water Suppression ¤ ¤ ¤ Spark Detection SECOND STAGE ANDTERTIARY PROCESSING ¤ ¤ ¤ ¤ Electrical Maintenance ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

the mistsystem. for toensuresufficientflowispresent be checkedperiodically engineer for adviceand/orguidance. for engineer youconsult withyourlocalelectricianorelectrical advised that ElectricalCodeasapplicable. National Refer toappropriate Itis asnecessary. shouldbeupdated diagrams All electricaloutletsshouldbemapped. andtechnical Suchmaps repaired orreplacedasnecessary. Electrical connectionsmustbecheckedonaregularbasisand anignitionsource. creating uporarcthereby heat Loose, wornorbrokenelectricalconnectionscomponentsmay Refer tomanufacturer’s properprocedures. for recommendations supply,The water wellorcitysupplied, whetherprivate should properoperation. affect restrictions whichmay or Water damage for linesshouldbeinspectedregularly supply properfunctioning. maintained for Water shouldbe coolingthegrinder mistsystemsusedfor patterns. sufficient flowandproperspray nozzlesneedtobeconductedensure Periodic checksofspray use for appropriate Ensure pipelinesareconstructedofmaterial ofthisfiresafetyequipment. optimal performance toensure Periodic inspectionandtestingshouldbeperformed multiple sparkcount). (based uponasingleor granulator to extinguishthefirein The sparkdetectorcanalsobeinterlockedwithadelugevalve downstream. frombeingconveyed material burning to preventany on theexhaustductfromgranulator Consider installingasparkdetectionandsuppressionsystem infiresuppressionsystems. 

¤ ¤ Mechanical Maintenance ¤ ¤ ¤ ¤ ¤ Hot Work Program ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

before theofday.before the wire penetrating electricalcomponentsandcausingsparks. the wirepenetrating buildupfromfrictionor components isessentialtopreventheat ofwireonthevarious Periodic cleaningtopreventaccumulation outprocedurespriortoperforming properlockout/tag Observe Refer to Appendix additionalinformation. A for cutting,When possibleavoid welding, 2-4hours grinding dispersion ofsparks. dustcollectionequipmenttomitigate turnoff Where applicable whenmaintenanceonequipment Should alsobefollowed Required whenevertorching, operations weldingorgrinding buildupfromafailure. to minimizepotentialheat properoperation Bearings shouldbeinspectedandmonitoredfor buildup orotherfailurewhichcouldcauseafire. withoutcausingexcessiveheat equipment canbeoperated and boxes toensurepropermaintenancehasbeenperformed Inspect drivecomponents, suchasbelts, clutchesandgear any maintenanceontheseitems. any is alsorequired. are performed.

DUST CONTROL be practicedwhenworkinginandaround thisequipment. pose anextreme explosivehazard andcare should of thematerial.Theequipment,aswell asthedust,can in adustcontrol area duetotheextreme explosivenature Extreme cautionshouldbeexercised whenworking processing andneedtobemanaged. Large quantitiesoffinesandfiber are generatedduring especially whenperformingsecondaryortertiarygrinding. Dust control isanintegralpartoftire processing, DUST CONTROL HOUSEKEEPING Inspections A housekeeping program should be implemented to minimize buildup of dust. Employees ¤¤ Collector and ductwork should be inspected regularly for proper air flow and buildup need to be trained in proper cleaning procedures. Housekeeping activities should be of dust material. Sufficient air volume and conveying velocities must be maintained sufficient to prevent buildup of material or contaminants in the area. to prevent material accumulation in the ductwork. ¤¤ Accumulations of fugitive dust on surfaces should be removed on a regular basis in a ¤¤ A program should be established for periodic inspections of the filter cleaning manner that minimizes the generation of dust clouds. components for proper adjustment and operation. ¤¤ Vacuuming is one method of dust removal. Personnel should be aware that vacuuming ¤¤ If the dust collector system is equipped with a fire suppression system, periodic a hot ember into vacuum may create a high explosion risk. testing should be performed to ensure proper operation of associated components. ¤¤ When using compressed air to blow down equipment, use less than 30psi, and take ¤¤ Air lock bearings and seals should be inspected on a regular basis. extreme care not to create a dust cloud. ¤¤ A program should be established for periodic monitoring of pressure gauges. ¤¤ When moving dust or fiber with a broom or scrapers, it is advisable to use stainless or aluminum tools to minimize the potential of creating a spark. Electrical Maintenance ¤¤ Ensure that dust collectors, cyclones, fans, ductwork and associated equipment DUST COLLECTORS CONTAINING FILTRATION MEDIA are properly grounded to eliminate the buildup of static electricity. Dust collectors on grinders serve the dual purposes of removing excess dust from ¤¤ If a section of duct is connected via or rubber hose, ensure that grounding the grinder and providing airflow to help reduce heat buildup in the grinder. The dust is accomplished on both sides of the connection. collector should be of sufficient size to provide the proper airflow for heat extraction ¤¤ Note instances where static electricity has been observed and develop a program and dust collection. to eliminate as much static as possible. Dust and other undesirable materials are collected and transported to a central location ¤¤ Loose, worn or broken electrical connections or components may heat up or arc for reprocessing or disposal using various techniques. It is not uncommon to pick up thereby creating an ignition source. sparks or embers at the dust source and transport them along with the dust through the ¤¤ Electrical connections must be checked on a regular basis and repaired or system. Proper installation and operation of the dust collection system can significantly replaced as necessary. reduce the potential for fires. A fire or explosion in a Bag House can occur due to sparks ¤¤ Refer to appropriate National Electrical Code as applicable. It is advised that you or burning material (fluff or dust) that is transported from the process area to the dust consult with your local electrician or electrical engineer for advice and/or guidance. collector through exhaust (pneumatic) ducting. ¤¤ All electrical outlets should be mapped. Such maps and technical diagrams should be updated as necessary. Safety Precautions Mechanical Maintenance ¤¤ Dust Collectors and Baghouses should be located outside the building whenever possible. ¤¤ Observe proper lockout/tag out procedures prior to performing any maintenance on these items. ¤¤ Dust Collectors must be properly vented for explosions as per NFPA 68. ¤¤ Inspect drive components, such as belts, clutches and gear boxes to ensure that ¤¤ The use of a backdraft damper or other isolation device upstream of the dust collector proper maintenance has been performed and equipment can be operated without should be considered to prevent explosion propagation back into the plant. causing excessive heat buildup or other failure which could cause a fire. ¤¤ Observe proper lockout/tag out procedures prior to inspection or performing any ¤¤ Bearings should be inspected and monitored for proper operation to minimize maintenance on these items. potential heat buildup from a failure. ¤¤ Smoking in the dust collection area should be prohibited at all times. ¤¤ If engineering controls cannot adequately control dust concentrations within Hot Work Program guidelines established by OSHA, respirators should be used. ¤¤ Required whenever torching, welding or grinding operations are performed. ¤¤ Utilize a spark detection and suppression system to detect and suppress sparks ¤¤ Should be followed when maintenance on equipment is required. or burning particulate in the duct work to prevent ignition of a fire or explosion ¤¤ Where applicable turn off dust collection equipment to mitigate transmittal of sparks. in the collection unit. ¤¤ When possible avoid cutting, welding, grinding 2-4 hours before the end of the work day. ¤¤ Consider installing a deluge valve and nozzles that can be automatically activated ¤¤ Refer to Appendix A for additional information. by heat detectors in the Bag House or by manual release. ¤¤ Follow appropriate confined space practices as outlined by OSHA. CYCLONES ¤¤ Refer to manufacturer’s guidelines for changing filter bags. Cyclones are cylindrical dust collectors without filtration media, used to separate material ¤¤ Refer to the manufacturer’s recommendations for proper installation and from the airstream by means of centrifugal force. They are usually placed in front of the maintenance procedures. Bag House. ¤¤ A proper employee training program should be established to ensure employees understand the potential hazardous nature of the procedures and materials to be Inspections operated and handled. ¤¤ Air lock bearings and seals should be inspected on a regular basis. ¤¤ A program should be established for periodic monitoring of pressure gauges. CONVEYING simpler systemtobeutilized. smaller sizeproducts, asitallowsamore compactand are thebestchoice.Anotheroptionistouseairflowfor applications, rubberbeltconveyorsorscrew conveyors is essentialtotheproper operationofafacility. Formost Conveying materialthroughout theprocessing system CONVEYING CONVEYING Smoking in the conveying area should be prohibited at alltimes. areashouldbeprohibitedat Smoking intheconveying and handled. tobeoperated procedures andmaterials ofthe hazardousnature employees understandthepotentially toensure shouldbeestablished A properemployeetrainingprogram and maintenanceprocedures. Refer tothemanufacturer’s properinstallation for recommendations maintenanceontheseitems. any performing outprocedurespriortoinspectionor properlockout/tag Observe SAFETY PRECAUTIONS this information. arenotedandrecord defectsthat any Repair orplaceasnecessary buildupfromafailure. minimize potentialheat to properoperation Bearings shouldbeinspectedandmonitoredfor which couldcauseafire. builduporotherfailure withoutcausingexcessiveheat be operated andequipmentcan ensure propermaintenancehasbeenperformed Inspect drivecomponents, suchasbelts, clutchesandgearboxesto maintenance ontheseitems. any outprocedurespriortoperforming properlockout/tag Observe MECHANICAL MAINTENANCE adviceand/orguidance. for engineer youconsultwithyourlocalelectricianorelectrical advised that ElectricalCodeasapplicable. National Refer toappropriate Itis asnecessary. shouldbeupdated diagrams All Electricaloutletsshouldbemapped. andtechnical Suchmaps repaired orreplacedasnecessary. Electrical connectionsmustbecheckedonaregularbasisand anignitionsource. creating uporarcthereby heat Loose, wornorbrokenelectricalconnectionscomponentsmay ELECTRICAL MAINTENANCE APPENDIX A SUGGESTED PROTECTIVE EQUIPMENT should bedone: procedures hotworkthefollowing After undertakingany Before undertaking any procedure the following shouldbedone: procedurethefollowing undertakingany Before GRINDING, ORPLASMACUTTING ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ Identify potentialhazards USE WHENPERFORMINGTORCHCUTTING, WELDING, ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ fire suppressionequipment Ensure atrainedspotterhasappropriate ¤ Prepare Area ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

Hearing protection asneeded hazard ofarespiratory (unlesstheabsence Respirator light providesprotectionfromultraviolet Eye/face shieldingthat Fire retardantlongsleevedshirt offullbodyworkclothing Fire retardantcoverallsorotherform Fire retardantgloves Oil resistantclothingorcovering guards Steel toe/steelshankworkbootswithmetatarsal Safety glasses Hard hats Clean uparea Inspect area Fire extinguishers Water supplies Clean areaofdebris Flash burn Bright flash Sharp objects/edges Repetitive motioninjuries Oil andHydraulicfluids Hot environment Hazardous fumes gasesorvapors Flammable Fire fallingobjects Heavy Explosive atmosphere Burns Back strain Aerosolized particles can beproven) material beingcut) material of4to6,(shade ratings dependingon thethicknessof APPENDIX A–HOT WORK

materials. orcombustible freeofflammable Areas mustbereasonably Compressed gascylindersmustneverbemovedviamagnet. monitored inaccordancewiththecorrespondingregulation(s). Where hazardouslevelsexist, workers shouldbeprotectedand include,These materials limitedto: butarenotnecessarily to determinethelevelofpotentialexposurehazardousmaterials. torchcuttingoperations shouldanalyze andoperators Managers incloseproximitytohotworkoperations. available markedandreadily fireextinguishermustbeplainly Portable SAFETY PROCEDURES piping orhosetoprevent Approved protectiveequipmentmustbeinstalledintothefuelgas TORCH SPECIFICPRECAUTIONS ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

Zinc oxide Nitrogen dioxide Nickel vapor Mercury oxide Magnesium Iron oxide Chromium Carbon monoxide Beryllium Cadmium Lead system Excessive backpressureofoxygeninthefuelgassupply system ofaflashbackintothefuelgassupply Passage system Backflow ofoxygenintothefuelgassupply

APPENDIX A Remove regulators before movingortransporting cylinders. before Remove regulators Store cylinders ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ includes,gases that aminimum: at ofcompressed handling andstorage awrittenprocedurefor Establish SAFETY PROCEDURES ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

Oxygen and fuel gas cylinders must be separated by either: by Oxygen andfuelgascylindersmustbeseparated fromfuel gascylinders Oxygen cylindersstoredseparately Valve endup; With valvesclosed; inplace; With valveprotectioncaps Away fromoil, petroleumproducts; orany grease Away ingeneral; fromcombustiblematerials Away fromheat; andmarkings Maintenance ofcylinderlabels Maximum cylinderpressure » » or othercombustiblematerials; » »

resistive rating of at leastone-halfhour. ofat resistive rating afire least5feethighhaving A noncombustiblebarrierat of20feet; A physicalseparation APPENDIX A–HOT WORK

cylinders, andthoseproceduresshouldaddress: useofcompressedgas Written proceduresshouldbedevelopedfor part ofanelectricalcircuit. mightbecome wherethey notbeplacedinalocation Cylinders may eachmanifold. required for are inuse. Foramultiplecylinderinstallation, onesuchdeviceis only wrenchmustremainonthevalvestemwhencylinders nonadjustable fixedhandwheels,For cylindersnothaving akey, handleor ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

one-half ofoneturnthespindle. Only a friction spark lighter may beused to lightatorch. africtionsparklightermay Only An acetylenecylindervalveshouldbeopenednomorethan Stand toonesidewhenopeningthecylindervalve. surfaces ofdebris. toclearthe thenclosedimmediately should beopenedslightly toacylinder valve, connectingtoaregulator Before thevalve hand, by only Cylinder valvesshouldbeoperated andclosed must bekeptfreeofoil, orotherpetroleumproducts. grease Cylinders, valves, couplings, regulators, hosesandapparatuses only handtight. only

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