Welcome to the Inaugural Grain Handling Safety Stand Down ...€¦ · Welcome to the Inaugural...

Welcome to the Inaugural Grain Handling Safety Stand Down

Engulfment Education and Prevention Seminar

2

THANK YOU SPONSORS!!

Grain Engulfment History/Background.

Types of engulfment and root causes.

Engulfment Prevention Methods/Best Practices.

Removal of grain from bins.

Methods for keeping employees out of bins.

Management Practices, Policies and Procedures.

Bin Entry Procedures/Permits

Topics for Discussion

Started collecting data in 1977. Initially focused on grain entrapments . Expanded focus to all confined spaces in

2011.

All confined space incidents collected are entered in the Purdue University’s Agricultural Confined Space Incident Database (PACSID).

Summaries on incidents have been published annually for the last decade.

Purdue University’s Work

Grain Entrapments 2006 to 2016

All Agricultural Confined Space Incidents for 2016

Grain Bin

Silo

Hopper bottom feed bin

Grain Trailers

Gravity Boxes/Wagons

Where do Grain Engulfment Incidents Occur?

While a truck was being unloaded they somehow fell into the canola seed.

Two girls died at the scene as responders attempted to resuscitate them for over two hours.

Third sister was airlifted to hospital in critical condition where she died the following day.

Three Young Sisters Suffocate After Being Buried Under Grain at Family Farm

Children and youth account for approximately 20% of all documented cases, most resulting in fatalities.

Purdue Engulfment Study 1964 - 2014

Historically, 70% of the documented entrapments have occurred on exempt farms, while 30% occurred at non-exempt commercial facilities.

There is a direct relationship between out-of-condition grain and a greater probability of entrapment.

Other Findings

Increase volume/production of grain and feed being handled.

Larger capacity storage facilities.

Larger capacity handling equipment.

Increase in the volume of exempt, on-farm storage.

Longer term storage.

Contributing Engulfment Factors

Out-of-condition grain/feed.

Workers entering storage spaces alone.

Farmers storing wetter corn to reduce energy costs.

Changing workforce at commercial facilities lack agriculture background.

Expanded use of grain for energy production.

Contributing Engulfment Factors

How Does Engulfment Happen?

Flowing Grain

Moving/flowing grain acts like “quicksand”

Buries the worker in seconds.

From time auger

starts, you have 2-3

seconds to react.

In 4-5 seconds

you are trapped!

In 22 seconds you

are completely

buried!

Bridged or Crusted Grain

“Bridging” - Grain forms crust over top layers and creates an empty space beneath.

Bridge can collapse when a worker walks on it and bury them.

A grain pile can avalanche unexpectedly

on its own or when the worker attempts to

dislodge it.

Avalanching Grain

Engulfment/Entrapment

Grain engulfment exposes workers to suffocation hazards.

Leading cause of fatalities.

Suffocation can occur from:

Breathing in grain which blocks the respiratory system.

Hazardous atmospheres.

Engulfment/Entrapment

Grain engulfment also exposes workers to crushing or strangulation hazards due to the extreme weight or force being exerted on the body by the grain. This can cause……

Inability to breathe over time

Irreparable damage to internal organs

Buildup of toxins in the body

Force Required to Extract a Victim From Grain

The effort

required to pull

someone from

grain is a major

hindrance to a

quick rescue

Do not use

mechanical

devices to

remove a victim

from grain

Engulfment Survival Rate

Plugged Sump

Grain unloading problems (walking the grain)

Installing Bin Sweeps

Digging out Bin Sweeps

Bin Inventory

Reasons for Entry in Bins Containing Grain

What are some of the reasons that cause you to enter into a grain bin?

Employees are working in bins with TOO MUCH GRAIN!!!

ROOT CAUSE OF ENGULFMENTS?

Get as much grain out of the bin as possible before employees enter to perform work.

Keep employees out of bins as much as possible.

How do we know when we’ve removed enough grain from a bin to eliminate an engulfment hazard?

Engulfment Prevention Methods

What can be done to correct this?

There are documented angle of repose figures for all varieties of flowable solids including grain.

The angle of repose is based on the fact that when a particular substance reaches it angle of repose the material will no longer flow naturally as long as it is not disturbed by any outside factors.

Angle of Repose

Different grains have different angles of repose.

Corn – 21 to 23 degrees

Wheat – 25 to 27 degrees

Soybeans – 25 to 27 degrees

Oats – 28 degrees

Barley – 28 degrees

Angle of Repose

http://www.bae.umn.edu/extens/postharvest/bushels.html]

Much of the grain industry is of the opinion that once the grain has stopped flowing, it has reached it’s “angle of repose” and it is “safe” to enter.

How do you know if the grain has reached its angle of repose?

Angle of Repose

Many say they can tell just by looking.

This is not a very safe or accurate method.

If the grain is above or greater than its normal angle of repose there is generally a reason why and going into a bin under this condition exposes a person to an engulfment hazard.

Angle of Repose

There are laser angle measuring instruments and phone apps available that can be used to measure the angle however, this requires a person to enter the bin and be exposed to a potential engulfment.

Angle of Repose

Instruments such as this one shoot out a laser beam and locks in the angle.

What some are doing is once the bin is empty, going to the center of the bin and measuring the angles of the different grains stored in the bin.

Angle of Repose

Then different colored rings are painted around the inside walls of the bin. Each color denotes a different grain.

Once the grain has been pulled down and the color is visible then the angle of repose can be verified by simply looking.

Once the grain has reached its angle of repose the engulfment hazard has been eliminated.

Angle of Repose

There are also charts that have been developed based on bin diameter to help assist with determining the angle of repose without the need to enter the bin.

Using the chart you can determine how high the grain should be at the bin sidewall at its normal angle of repose.

Angle of Repose

OATS, BARLEY

Many older bins have small sumps (12”x12”).

Many only have sumps on one side or half the bin diameter.

These bins typically have a significant amount of grain left inside when pulled down.

Size and Number of Bin Sumps

Newer bins now have:

Sumps that go completely across the full diameter of the bin.

Increased number of sumps on each side.

Increased size of sump (up to 2X larger)


Companies that are serious about reducing engulfment hazards are:

Identifying existing bins where sumps can be added across the full diameter of bin.

Putting in the largest available sumps in new bins.

Increasing both the number and size of sumps in existing bins.



Modifying and adding sumps will assist in removing as much grain as possible which in turn minimizes the engulfment hazard.

Run all bin fans while unloading grain from bin.

Air movement through the grain along with the fan vibrations has been found to remove more grain from the bin than if the fans are not running.

Several companies have incorporated this practice into their grain unloading procedures.

Running Bin Fans

Before employees enter a bin you want to be sure that you have removed as much grain as possible.

The angle of repose is at least equal to or less than the documented angle for the grain.

These measures will help to minimize the engulfment hazard.

Getting Grain Out of Bins

Sending employees in a bin to clear a plugged center sump is a common practice and one of the leading causes of engulfment fatalities because once the plug is cleared the grain will immediately begin to flow and engulf the person.

Keeping Employees Out of Bins Plugged Center Sumps

One method that has been found to be effective in clearing plugged center sumps is the installation of rods inside of a pipe with finger-like projections on the end.


Rods move front and back within pipes.

Fingers can rotate up and down to break up plug.

Since this installation, the company has not had to send anyone inside a bin to clear a plugged sump. Very easy and economical to install.

Rods are operated by employees from outside the bin and the fingers are positioned the same as those inside the bin.

For bins with tunnels employees are oftentimes able to access the center sump discharge chute.

The access panel can be removed and rods used to dislodge or clear the plug from underneath.

Companies have found this to be very effective in clearing out the sump.


Access panel.

All of the above conditions present serious engulfment hazards to employees when they enter the bin.

These hazardous conditions are being addressed by companies as follows:

Keeping Employees Out of Bins Bridged, Cliffed, Caked or Towers

This tower of grain is 65’ tall.

Utilize contractors who specialize in removing these types of grain hazards. Benefits include:

Eliminates stranded investment expense in equipment and training costs.

Contract workers are experienced in operating this equipment and are efficient with its use.


Contract Out the Work

Mole Master™ and Pneumat Services

Companies that are serious about keeping employees out of bins will use either of these options to deal with these grain issues.

Both options will likely require that the bin be cut open.

A portable auger can be inserted in the opening to both break up and unload the grain from the bin.


Use of Grain Vacuums and Portable Augers

Grain vacuums can accomplish the same end result.

Depending upon conditions you may have to make several cuts or openings in the bin to break up and remove the grain.



Another reason employees enter a bin is to set up or dig out sweep augers.

Zero entry sweep augers are available by many manufacturers.

These augers are powerful enough to start up and dig out of the grain without employees having to enter the bin at all.

Keeping Employees Out of Bins Zero Entry Sweep Auger Systems

Grain properly dried when harvested.

Track bin temperatures through use of temperature cables so bin fans can be operated as needed to keep grain in the best condition possible.

Be diligent in maintaining bins to prevent leaking.

Prevention Methods Production Management Practices

Eliminate top entries into bins if at all possible.

Some companies are locking all top bin hatches with the Facility Manager being the only person with the key.

Side entries are oftentimes safer but not always.

Prevention Methods – No Top Entry

OSHA does allow top entry from above the grain but requires the use of a safety harness and lifeline or a boatswain chair.

BEWARE!! This is nearly impossible to accomplish.



Most roof designs for steel bins do not allow for an adequate anchorage point for fall protection systems or the use of a boatswain chair.

The anchor point must be directly overhead at all times which doesn’t allow the person much freedom of movement.

Some fall protection devices such as retractable lifelines will not work.

The one benefit to wearing a harness and lifeline is if you do become engulfed the rescuers can find you easier by following the lifeline.


The person on the inside of the bin is secured to the outside of the bin.

The person on the roof can pass instructions and assist in lifting.

The person on the ground can go for help or assist in pulling.

Illustration of successful rescue of worker during "bridging" condition.

DO NOT ATTEMPT THIS!! IT WON’T WORK!!

Anticipate that you will have problems ahead of time.

Have a plan in place.

Have access to the necessary equipment.

Train employees ahead of time so adequately prepared.

Prevention Methods Production Management Practices

Develop a company and/or farm Bin Entry Program. Permit or safety checklist Lockout/Tagout Atmosphere Testing Prohibit Top Entry Availability of rescue equipment Alternatives

Prevention Methods - Bin Entry Program

Required in commercial grain industry.

Issued by the employer OR authorized person.

Authorized person ensures permit requirements met.

Best Practice (Farmers included) – always fill out permit or checklist.

Prevention Methods - Bin Entry Permit

Lockout ALL energy sources.

ALL conveying equipment.

Only authorized/trained persons.

Protects from unexpected start-up.

Prevents dangerous flowing grain.

Lockout MUST be done prior to entry!

Bin Entry Permit – Lockout/Tagout

Bin Entry Permit – Lockout/Tagout

Best practice for EVERYONE!

Failure to lockout is one of the leading causes of engulfment!!

Oxygen content.

No less than 19.5%

No greater than 24.5 %

Toxic Gases

Hydrogen Sulfide (H2S)

Combustible Gases and Vapors

Less than 10% of the lower explosive limit (LEL)

Requires the use of a multi-gas monitor to check for these potential hazards.

Cannot detect these using our own sense of smell.

Hazardous atmospheres generally result in multiple fatalities.

Bin Entry Permit Atmospheric Testing

NEVER EVER go in a bin ALONE!

Always have a standby person stationed at the entry point at all times while persons are inside a bin.

Standby person doesn’t leave his post until everyone inside the bin has exited.

Standby person must always have a cell phone or other means of communication (2-way radio) to call for help in an emergency.

Bin Entry Permit

Must have a rescue plan in place.

Must also have rescue equipment available that is suitable for the bin, silo or tank.

Bin Entry Permit - Rescue

Grain Recue Tube

Bin Entry Permit

A member of top management must visually verify that the grain does not pose an engulfment hazard, review the entry permit to ensure all precautions have been taken and sign the permit authorizing the entry.

Yes, zero entry sweeps, modifying bin sumps, purchasing or renting grain vacuums and using contractors can cost a lot of money.

It can also cost a lot of money when OSHA issues PENALTIES for engulfment incidents.

It Costs too Much to Comply!

It costs too much to comply!

Unfortunately it’s the family who pays the ultimate price when an engulfment results in a fatality.

Remove as much grain as possible before allowing entry. This can be accomplished by:

Adding more sumps.

Increasing the size of the sumps.

Running bin fans while unloading grain.

In Summary

Devise a method to accurately determine if the grain has reached its angle of repose.

Try to keep employees out of bins as much as possible by: Finding ways to clear plug sumps from outside the

bin.

Using contractors for removing bridged, caked, cliffed or grain towers inside bins.

In Summary

Using grain vacuums or portable augers to remove grain when engulfment hazards are present.

Installation of zero entry sweep augers.

In Summary

Implement the following management practices, policies and procedures to prevent engulfment: Properly dry grain and utilize state of the art

methods for monitoring grain to keep it in good condition at all times.

In bad harvest years anticipate unloading problems and develop a plan.

In Summary

Prohibit top entries into bins.

Develop a bin entry program and make sure all hazards are properly addressed on the entry permit including precautions taken to prevent engulfment.

Require top management to perform a visual inspection and sign off on permit prior to entry.

In Summary

Compliance Assistance Specialists

Kelly Bubolz Leslie Ptak U. S. Dept. of Labor - OSHA U. S. Dept. of Labor - OSHA 1648 Tri Park Way 4802 E. Broadway

Appleton, WI 54914 Madison, WI 53716

(920) 734-4521 (608) 441-5388

Mary Bauer Jim Lutz

U. S. Dept. Of Labor - OSHA U. S. Dept. of Labor - OSHA

1310 W. Clairemont Ave 310 W. Wisconsin Ave

Eau Claire, WI 54701 Milwaukee, WI 53203

(715) 832-9019 (414) 297-3315

Contact Jim Nolte, WABA Safety Director with any questions or suggestions you may have regarding engulfment hazards or issues.

Phone: 608-223-1111

Email: [email protected]

Wisconsin Agri-Business Association

QUESTIONS??

Welcome to the Inaugural Grain Handling Safety Stand Down ...€¦ · Welcome to the Inaugural...

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