October 25, 2017
Paper Machine Hazards
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- Learning Management Systems
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- Custom Paper Manufacturing Training
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Paper Machine Hazards
Any paper machine presents a set of hazards to the employees who work with and around it. By if employees are aware of these hazards, are able to identify them (and control them when necessary), and know how to work safely in the presence, they can greatly decrease any measure of risk related to those safety hazards in paper manufacturing. We'll list some specific types of hazards below, and give specific types for working safely with them, but in addition it's always a good idea to keep the following best safety practices in mind:- Never work on or around a paper machine without proper operational and safety training
- Always follow approved job procedures for each job task
- Always prioritize your own personal safety above any job task; don't work if a task is unsafe
- Always assume responsibility not only for your own safety, but for the safety of everyone in the work area--remember safety is a group activity
- Always ensure paper machines receive proper preventive maintenance on a routine basis
- Make sure all non-preventive maintenance needs are addressed and corrected as soon as they are identified
- Always use good housekeeping to limit unnecessary hazards in the work area
Specific Paper Machine Hazards
Now let's begin to look at some of the most common types of hazards at a paper machine.Pinch Points
A pinch point is pretty much what it sounds like: A point where a person can get pinched between moving parts or between a stationary object and a moving part. But the pinch isn't a cute little love tap. Pinch points can lead to dangerous, crushing injuries, leading to permanent disability, amputation, and even death. Pinch points are places where a person or a body part can be caught or crushed by equipment movement. Paper machines often have pinch points:- Between two different moving parts
- Between a moving part and a stationary part
- Around and beneath loads being transported--for example, under a large paper roll
- Between mobile equipment, such as a forklift or clamp truck, and other machinery or objects
Nips
A nip is a specific type of pinch point created by rotating or reciprocating parts. The hazard is that a finger or other body part can get pulled into the nip area by the rotating motion, leading to a severe crushing or cutting injury (or, again, even death). Nips can be especially hazardous because they're often in areas where people feed materials into the paper-making process, make adjustments, or must add lubricants. Nips are common at paper machines at adjacent rotating rolls, where a rotating roll and a moving rope or web come together, or around moving ropes and rope sheaves. Nips are a type of pinch point usually associated with adjacent rotating rolls, a rotating roll and a moving rope or web (like a fabric or sheet of paper), or moving ropes and rope sheaves. Nips are hazardous to fingers and hands because they are often present where materials must be fed into the process or at adjustment and lubrication points.Sharp Surfaces
Sharp surfaces can cause cuts, scrapes, deep wounds, and even amputations. There are many sharp surfaces around a paper machine, ranging from box or utility knives employees may carry around to things like doctor blades and log saws.- Use caution when working with your hands. Injuries from sharp surfaces are most commonly suffered on the hands.
- Always use a tool with a sharp surface, such as a knife, blade, or saw, only as it was designed to be used. Don't be careless and don't improvise.
- Be careful when moving around the moving fabrics of a paper machine. You may not think of this initially, but the edge of that moving fabric is a sharp surface and it can cause serious cutting injuries.
- Use can when handling doctor blades and worn creping blades. Wear all of the required personal protective equipment and follow all of the standard operating procedures.
- Be cautious when performing tasks that are new, unfamiliar, and/or not routine for you. Keep an eye for sharp surfaces such as metal burrs, protruding bolts, and other sharp or rough edges.
Hot Surfaces
Paper machines and paper manufacturing facilities in general include a number of hot surfaces, which of course can cause dangerous burns. Surfaces may be hot because they are designed to either produce or transfer heat, but they may also be hot simply due to friction from moving moving parts. Possible locations of hot surfaces on a paper machine include steam lines, steam traps, and pumps. You may also find hot surfaces near a paper machine; an example might be the motor of a forklift.Slip, Trip, and Fall Hazards
Slips, trips, and falls cause many of the injuries suffered in nearly all workplaces, including paper manufacturing plants. Injuries from slips, trips, and falls can range from nothing more than wounded pride, to cuts and bruises, broken bones, paralysis, and death. Even from a fall of only a few feet or from ground level.- Debris such as broke paper and scraps left on the floor
- Wires and cords left on the floor or in walkways in an unsafe manner
- Fluids left on the floor, such as water near the wet end of a paper machine
- Missing, broken, or poorly designed guard rails
- Missing, broken, or poorly designed steps
- Improper use of ladders
- Failure to use fall protection
- Distraction and inattention to surroundings
- Hurrying
Particles Suspended in the Air
During the papermaking and converting processes, paper fiber dust is created, becomes airborne, and may eventually accumulate on machines or the ground. This dust presents several hazards:- On a walkway, it can be slippery and may contribute to slips, trips, and falls
- It can get lodged in an employee's unprotected eye
- It increases the risk of fire or explosion when airborne (check our "combustible dusts" training sample below)
- A worker may inhale the dust, leading to respiratory problems
Noise Hazards
Loud noises and noises that continue for extended periods of time can severely harm your hearing. Such noises are common in many manufacturing plants, and that includes paper manufacturing facilities.Hazardous Chemicals
There are many hazardous chemicals used in papermaking facilities as part of the papermaking process. Quite a few of them are very hazardous. Just a few are listed below:- Anhydrous Ammonia
- Chlorine Dioxide
- Formaldehyde
- Hydrogen Sulfide
- Turpentine
- Anhydrous Ammonia Awareness
- Chlorine Dioxide Awareness
- Formaldehyde Awareness
- Hydrogen Sulfide Awareness
- Turpentine Awareness
- Safety Showers and Eye Washes
- Process Safety Management (PSM)
Confined Space Hazards
Confined spaces present many hazards, including some that can lead to death. But perhaps we should begin by explaining what a confined spaced is. OSHA says a confined space is a space that:- Is large enough for a person to get into it and work
- Has limited or restricted means for entry or exit
- Is not designed for an employee to be in it continuously
Water and Air Hoses
Hoses for carrying air and water are commonly located all throughout a paper machine facility. These hoses present a set of hazards. For one thing, a hose can get caught up in the rotating parts of a machine nip. If a hose gets caught up in a rotating nip, and then also wrapped around a person, the person may ultimately be dragged into the rotating nip as well, leading to severe injury or death. Following safe work procedures when using a hose can help prevent this: when using a hose, always position the hose so it's not behind you and not wrapped (even loosely) around any part of your body. Pressurized hoses also present a different hazard. If a high-pressure hose is turned on quickly, it may be jerked out of the worker's grasp or cause the worker to lose balance and fall. As a result, it's a best practice to always open supply valves slowly. Another type of hazard comes from pressurized hoses. If a high pressure hose is turned on too quickly, the hose can be pulled from the worker's grasp or cause the worker to lose his/her balance. This may also cause the worker to lose control of the hose. In a case like this, the high pressure will cause the hose to whip around, possibly striking workers. These type of hose-whipping accidents can cause very severe injuries. To prevent this sudden jerking of the hose, open supply valves slowly. Finally, it's always good to practice good housekeeping to prevent slips, trips, and falls or entanglements. Put hoses away in proper, coiled fashion when you're not using them.Fire Hazards
Fires are a serious safety issue anywhere--at home or at work. And paper manufacturing facilities have some characteristics (namely: paper and other word products!) that make fires a serious hazard. In particular, the broke, litter, and dust at a paper manufacturing facility, all most commonly found at the dry end of the paper machine and near rewinders in the converting area, are specific fire hazards (as are the equipment that cause heat that could cause these materials to ignite). A fire can be a great safety issue anywhere. The most common fire hazards in a paper facility come from broke, litter, and dust being ignited. These materials are commonly found at the dry end of the paper machine and around the rewinders in the converting area.- Fuel, such as wood, paper, or flammable chemicals
- Heat, which might be created by any number of industrial processes
- Oxygen, which is generally all around us in the air
- An uninhibited chain reaction that allows the fire to continue
- Static electricity. This can cause sparks between moving webs and machinery.
- The build-up of broke or dust on hot steam or condensate lines.
- Broke contacting hot equipment or machine parts, including the motors of forklifts