“How to Properly Address Engulfment Hazards” 2010 Safety, Health and Environmental Quality Conference
2010 Safety, Health and Environmental Quality Conference July 28 & 29, 2010 • Omaha, NE “How to Properly Address Engulfment Hazards” by Wayne Bauer Director of Safety & Security at Star of the West Milling Co. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Historical Timeline for Grain Industry 1850-1880 Flathouses or warehouses with 2,000 – 5,000 bu. capacity were used for storing grain in 100 lb. bags and flour in barrels 1870-1925 Wood-crib type elevators were designed & built for storage of bulk grain 1899 A single experimental concrete grain tank (20’ dia.) was built for Peavey Grain Co. in Minneapolis 1908 Butler built first steel bins for government storage 1910 Zeleny Thermometer Co. developed the thermocouple cable for reading grain temperatures How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Evolution & History of Grain Bins (We Thank Harmon Towne for Bin History) • 1908: The federal government contracted with Butler Manufacturing to manufacture the first corrugated steel grain bins. • The first steel bins were small (12’ dia.) and not very tall. • Between 1955 and 1965, the numbers & sizes of steel bins exploded on farms. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Original Farm Usage How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Original Farm Usage How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Older Style Bins How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Transformation of Bin Designs How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Transformation of Bin Designs How does the – (R) Factor and resultant Convection Currents in the structures above compare? How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Bin Sizes Keep Increasing 1908 Mid 1960’s Today Diameter 12’ 36’ 48 60 - 75’ 90’ 105’ 132 - 156’ Sidewall Height 50’ 60’ 75’ 80’ - 84’ 84 - 94’ During the past 100 years bin sizes moved from 500 bu. to 1,340,000 bu./bin. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Capacity (bu.) 500 10,000 750,000 1,000,000 - 1,340,000 Residual or Non-Reclaim Grain How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Number of Steel Bin Manufacturers # of Steel Bin Manufacturers Units Shipped per Year 1965-1975 26 firms 150,000 2000-2010 10-12 approx. 40,000 2020 (projected) ~ 5 maximum How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Older Style Bins How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Older Style Bins How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Roof Peak Loads and Design Strength • The center peak load capacities have moved from 5 – 10,000 pounds to roof load ratings in excess of 50,000 pounds today. • The peak load capabilities, along with sidewall towers or supports made it possible to use loading equipment with capacities well over 20,000 bph. • We are not pulling grain out of these bins with 4”-6” augers anymore. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. When Are We Going to Get Our Arms Around This Problem of Grain Entrapment? Industry Entrapments (Farm & Off-Farm) 2010 2009 2008 2007 2006 Deaths “Reported” Entrapment Total number of Deaths Off Farm On Farms ? 38 34 33 20 ? 16 - ? est. 6 10 9 7 ? est. 10 - Source: Bill Field, Purdue University How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Deaths / Year Around (Off-Farm) Facilities as a Result of Grain Entrapment 6.6 / year for 6 years between 2004-2009 3.5 / year for 4 years between 2000-2003 This easily exceeds any number experienced from dust explosions during the 1960’s and 1970’s We had 54 fatalities from dust explosions in the 10-year period of 1978-87, for an average of 5.4 deaths per year. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Why Do These Incidents Keep Happening? 1. 2. 3. 4. 5. 6. 7. 8. We are producing more corn (13+ billion bu.) Holding corn for longer periods (4.5 billion bu. for ethanol) We let the grain spoil or go out of condition Bins are getting larger (up to 1.3 million bu.) Reclaim systems are not adequate for 80’, 105’, or 156’ bins No attention to restraint systems People are not offered “Hands-On” training We are not using progressive discipline How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. What Principles Do We Need to Stress in Future Training? 1. Develop a Zero Entry Mentality a. Maintain grain quality b. Use safer and more efficient reclaim systems 2. If you must enter – do not enter alone 3. Provide actual hands-on training every year for a. Entrants b. Attendants c. Local rescue response team 4. Utilize & post - Entry Permit properly - who is the Rescue Response Team? 5. Lockout & tag unloading equipment before entering 6. Secure the Lifeline properly a. Establish overhead anchorage point b. Minimize slack in line and use an unconditional tie-off. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Reclaim Systems & Sweep Augers Must be safer and more efficient Must operate effectively without entering bin How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Older/Inadequate Reclaim Systems How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Discharge Sump Holes 12” x 12” 144 sq. in. 24” x 24” 576 sq. in. What would it cost to increase the size of your discharge sump hole by 4 times? How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Why Do We Ignore the Reclaim Systems? 1. Size of bins keep getting bigger: - 60’ > 80’ > 105’ > 130’ > 156’ > ? 2. Center roof peak load capacities: - 5,000 lbs. > 50,000 lbs. 3. Receiving and load-out capacities: - 4,000 bph > 10,000 bph > 20,000 bph > 40,000 bph > ? 4. Size and spacing of sump discharge holes: - 12” x 12” every 20 ft. - Why aren’t they 24” x 24” every 10 ft. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Questions I Hear Frequently 1. How should we get started with a REAL program? 2. What kind of RESCUE equipment should I buy? 3. How much MONEY will it take? 4. How do I form a RESCUE TEAM? How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Where should your money go? What are the priorities? 1. $80-$150/person – ANNUAL hands-on training 2. $250-$325 – Good Class III Harness with four D-Rings 3. $375 – Bin entry kit 4. $250-$3,900 – Cofferdam 5. $200 – Atmosphere testing equipment for oxygen at minimum (Real threat vs. perceived threat) 6. $4,000+ – Rescue equipment for (6) person response team How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Forming New Best Management Practices / Consensus Standards & Design Parameters for New Construction We need a paradigm shift in our way of thinking. Following the practices and designs of the 1970’s will not work in the future. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Best Management Practices 1. Offer employees “hands-on” training every year. (Have they learned proper usage of equipment?) 2. Do you have classes booked for 2011? (Lock in qualified instructors and start promoting early) 3. Does this training involve local emergency response teams and 911? 4. Progressive discipline. What are the consequences if an employee ignores the safety procedures? How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Training Videos Two new videos coming within the next year from Oklahoma State University and SATRA - Dr. Carol Jones and Cherokee Strip connection - Mike Brink with Safety and Technical Rescue Association How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Grain Entrapment Prevention – Industry Binder How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Table of Contents for GEP Binder How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Applicable Standards • • • • Which are required? Which are voluntary consensus standards? What do they mean? OSHA (29 CFR 1910.146 / 29 CFR 1910.272) • • • • NFPA (National Fire Protection Association) (1983 / 1670 / 1006) ANSI (American National Standards Institute) (Z 117.1 – 1989) ASTM (American Society for Testing Materials) SPRAT (Society of Professional Rope Access Technicians) How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Consensus Standards vs. OSHA Compliance Regulations Quote from: “Confined Space & Structural Rope Rescue” “Consensus Standards such as the NFPA, ASTM, SPRAT and ANSI are dedicated to improving the quality of operations and the overall safety of rescuers and victims in situations that would otherwise prove extremely hazardous.” “OSHA regulations are oriented towards performance rather than specifications. OSHA instead requires compliance of general rules by employers.” How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Forming & Training with Local Emergency Response Groups 1. Industry has to work more effectively with local fire departments 2. Have you offered training at your site? 3. Is your local emergency response group competent and equipped to respond in a timely manner? 4. Do they need 40 hours of rope training? 5. How would you respond if a local farmer is engulfed in a bin 3 miles from your site? How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Civil Liability and/or Litigation vs. OSHA Fines Who are you afraid of? • OSHA – Law/Regulation – citations and/or fines • Rescuers – put in harms way • Victim – lawsuits generated by family • Person dying in corn bin How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Is an OSHA fine of $1.6 million helpful? • “There is a new SHERIFF in town” • Will OSHA direct some money towards training in grain incidents? - (30-50%) of fines assessed - Susan Harwood grant How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. What Should New Design Parameters Address 1. Reclaim Systems a) Size and spacing of discharge sump holes b) Service tunnels c) Sweep augers 2. Access Doors a) Top of bin roofs b) Side doors 3. Ladders and Work Platforms 4. Restraint Systems a) Overhead anchorage point b) Secure and control life-lines How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Top Access Holes How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Top Bin Entry Doors Sketches furnished by Sioux Steel Company How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Top Entry Doors Consider moving doors for rescue purposes. How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Side Access Doors How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Side Access Doors How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Bin Entry Kits How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Passing Pulley in a 48’ dia. Tank How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Passing Pulley in a 72’ dia. Tank How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Fall Restraint System "Top Guard" - for use in 105' commercial bins Not Fall Protection Photos courtesy of GSI Group How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co. Grain Entrapment Prevention Conference/Symposium Join us in March of 2011 for a more in depth discussion of these issues. - Where: GSI training center in Assumption, IL - When: March 22-23 … Steel Bin Manufacturing Firms. March 24-25 … Grain Industry, Insurance and academics (Limited to 80 in each group) How to Properly Address Engulfment Hazards Presented by Wayne Bauer, Director of Safety & Security at Star of the West Milling Co.
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