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| Syllabus | |
| 1 | Intro. to the Course |
| 2 | Intro. to Gas and Oil Processing |
| 3 | Gas Processing Methods |
| 4 | Intro. to Water -Hydrolic Cycle |
| 5 | Intro. to Water -Part 2 |
| 6 | Power Generation/ Cogeneration |
| 7 | Electricity Transmission |
| 8 | 8 Missing |
| 9 | 9 Missing |
| 10 | 10Missing |
| 11 | Chemical, Reagents,Tools, Rigging |
| 12 | 12 Missing |
| 13 | Land Use and Reclamation |
| 14 | Instrumentation and Drawings |
| **** Final Exam***** | |
| Resources | |
| Staff E-mail | |
Introduction to Process
Technology
Lesson 11
Safety
Topic | Chemicals,
Reagents, Tools, Rigging | Basic
Terms
Objective:
Safety Topic-Hazard Communication General
OSHA s Hazard Communication Standard (HCS) is based on a simple conceptt employees have both a need and a right to know the identities and hazards of the chemicals they are exposed to at work. They also need to know what protective measures are available to prevent adverse effects from occurring. OSHA designed the HCS to help employers provide employees with this information.
When employers have proper information about the chemicals that their employees use, they can take steps to reduce exposures, substitute less hazardous materials, and establish proper work practices. These efforts will help prevent the occurrence of work-related illnesses and injuries caused by chemicals.
Chemical hazard evaluation
Chemical manufacturers and importers must evaluate chemicals and report hazard information "downstream" to your company. The reporting methods they use are labels on containers and material safety data sheets (MSDSs). Each chemical must be evaluated for its potential to cause adverse health effects and its potential to pose physical hazards such as flammability. An employer does not have to evaluate chemicals unless they choose to do so.
Employer responsibility
Your employer has implemented a hazard communication program designed to get information provided by manufacturers and importers to the employees. They must:
Obtain MSDSs and labels for each hazardous chemical the employees use.
Identify and list the hazardous chemicals in your workplace.
Design and put into place employee protection programs.
Develop and implement an effective written hazard communication program. The program must include provisions for container labeling, and collecting and ensuring MSDSs are available to employees.
Establish a training and information program.
Ensure the employees have access to MSDSs and the complete program
Written program
Employers must develop, implement, and maintain at each workplace, a written hazard communication program which has the following elements:
- container labeling and other forms of warning requirements,
- MSDS preparation,
- employee information and training methods,
- chemical lists,
- multi-employee workplace procedures, and
- nonroutine task and unlabeled pipe hazard notification procedures.
Material safety data sheets
Employers must have a MSDS in the workplace for each hazardous chemical that the employees use. MSDSs must be in English and include:
- specific chemical identity and common names,
- the chemical s physical and chemical characteristics,
- potential acute and chronic health effects and related health information,
- whether the chemical is considered to be a carcinogen,
- exposure limits,
- recommendations for appropriate protective measures, and
- emergency and first aid procedures.
Labels and other forms of warning
You must ensure that each container of hazardous chemicals in your workplace is labeled, tagged, or marked with:
- the identity of the chemical,
- appropriate physical and health warnings for the chemical, and
- the name and address of the chemical manufacturer, importer, or other responsible party.
The chemical name on the label must match:
- the name on the chemical s MSDS sheet, and
- the name on your list of hazardous chemicals.
The labels must be readable and in English.
Employee training
Employers must provide employees with information and training on hazardous chemicals in their work area:
- at the time of their initial assignment, and
- whenever a new physical or health hazard is introduced into their work area.
Information and training must include:
- understanding the requirements of the OSHA hazard communication standard,
- understanding the various components of your company s hazard communication program,
- knowing where the information is located in the company,
- knowing what operations at the worksite are using hazardous chemicals,
- being able to read and understand the information on the MSDSs and labels,
- determining how the chemical can impact your job, i.e., do you need a respirator or other PPE, do you understand the best work practices for a specific chemical?
Employee training
The hazard communication rule is very specific about an employer s information dissemination and training requirements (1910.1200(h)). See "Employee training" in the body text for requirements.
Where to go for more information. 29 CFR
1910.1200Chemical hazard communication.
Lesson 11
Chemicals
You will use many chemicals on the job. This section is to make you aware of the dangers seen and unseen of some of these materials.
The worker in the picture is in the process of mixing reagents. The white bag behind him holds 2000 pounds of zinc sulfate.The tank behind him holds 2500 gallons of water. When the zinc sulfate is added to the water and mixed, the solution will be used for depressing zinc mineral in the flotation process.
Your liver screens your blood removing toxins. Of course the toxins your liver can handle are those which occur in nature. The liver has difficulty with manmade chemicals and in some cases it fails under the assault of man made substances. Once your liver is wrecked, so are you.
Then everyday functions of the liver will be reduced.
Seemingly simple things like spray cleaners, parts cleaning baths, and even lubricating oils can cause damage that may not be apparent for years.
Never needlessly expose yourself to these substances. Wear gloves, breathing protection and skin protection to protect yourself.
Remember, every rule regarding the handling of these materials is the result of someone elses death or diminished life.
Use the MSDS to protect yourself.You can find MSDSs on the web by going to the following site, and searching for any chemical.
http://msds.pdc.cornell.edu/msdssrch.asp
Reagents
A Reagent is a chemical or a solution used to produce a desired chemical reaction.
An example of reagents are the chemicals used in developing photographs.
Cyanide is used in mining to leach gold from ore, and to depress pyrite in a flotation circuit. Xanthate is a reagent used in the mining flotation process for lead production.Copper sulfate is used in zinc flotation circuits to activate sphalerite (zinc mineral).
Reagents must be handled with care as they can be acidic, caustic, explosive, or toxic.
Reagents are often handled according to written procedures because the consequences of errors are so great. For example, the pH of a cyanide solution is critical. If the solution pH becomes too low, hydrogen cyanide gas (very deadly) can be generated.
Introduction to Rigging
Rigging is the hardware or equipment used to safely attach a load to a lifting device. The art or process of safely attaching a load to a hook by means of adequately rated and properly applied slings and related hardware.
Rigging is a critical job skill. Accidents and equipment damage due to faulty rigging can be severe and are almost totally preventable.
Common errors include
- lifting a load that is heavier than the rigging can handle
- improper use of rigging so that the load is dropped
- use of defective or damaged rigging equipment
The information for this course element will be taken from the DOE Hoisting and Rigging Manual.
First we are going to define some basic terms involved with rigging.
BREAKING STRENGTH: The measured load required to break a wire rope or chain.
CABLE: A term loosely applied to wire ropes, wire strands, manila ropes, and electrical conductors.
CLEVIS: A U-shaped fitting with pins.
COME-ALONG: A portable, hand-operated device consisting of a housing, a length of chain or wire rope, two hooks, and a ratcheting lever, that is used for miscellaneous pulling
DECELERATION STRESS: Additional stress imposed on a wire rope due to decreasing the load velocity.
DESIGN FACTOR: Ratio of ultimate strength to the design working stress.
FATIGUE: The tendency of a material to break under repeated stress.
ELASTIC LIMIT: Limit of stress beyond which a permanent deformation takes place within the material. This limit is approximately 55-65 percent of breaking strength of steel-wire ropes.
HOIST: A device that applies a force for lifting or lowering.
NONDESTRUCTIVE EXAMINATION (NDE): The development and application of technical methods to examine materials or components, in ways that do not impair future usefulness and serviceability, in order to detect, locate, measure, and evaluate discontinuities, defects, and other imperfections; to assess integrity, properties, and composition; and to measure geometrical characteristics.
PROOF TEST: A nondestructive tension test performed to verify construction and workmanship of slings or rigging accessories.
RATED CAPACITY: The maximum hook load that a piece of hoisting equipment is designed to carry; also the maximum load that an industrial truck or a sling, hook, shackle, or other rigging tackle is designed to carry.. NOTE: At the option of the user, a rated capacity can be assigned that is less than the design-rated capacity.
SAFE WORKING LOAD: Load that a rope may carry economically and safely.
SIDE PULL: That portion of a hoist pull acting horizontally when the hoist lines are not operated vertically
TURNBUCKLE: A device attached to wire rope for making limited adjustments in length. It consists of a barrel and right- and left-hand threaded bolts.
The use of a crane to hoist employees on a personnel lift platform is prohibited, except when the erection, use, and dismantling of conventional means of reaching the worksite, such as a personnel hoist, ladder, stairway, aerial lift, elevating work platform or scaffold, would be more hazardous or is not possible. Special rules apply to hoisting personnel which will be part of the homework assignment.
Overhead and gantry cranes include top-running single- or multiple-girder bridge with top-running trolley hoists (Slide 11-2), top-running single-girder bridge with underhung trolley hoists (Slide 11-3), and monorails/underhung cranes (Slide 11-4).
When first put in service the crane is load tested at between 100and 125 percent of its rated capacity
The hoist will have a hoist upper limit switch which must be tested once per shift. This limit switch prevents the hoist from being damaged by lifting too high thus causing a jam in the mechanism.This is commonly refered to as "two blocking".
Slide 11-05 shows the standard hand signals used. It is not necessary now to memorize the hand signals but students must be aware that the standard signals should be used to prevent accidents.
Radios are also used if available.
The weight of the load shall be determined prior to making the lift. During hoisting, take care to ensure that:
- The load is lifted slowly until it clears the ground or other support to minimize swinging.
- There is no sudden acceleration or deceleration of the moving load.
Slide 11-6 through 11-8 show several types of hoists. Hoists can be electric, air or hand powered. Look closely at these hoists. You will be asked to identify the different types later.
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Basic Terms of Maintenance, Operations and System
Components
Abrasion: Surface wear.
Acceleration Stress: Additional stress imposed due to increasing load velocity.
Area, Metallic: Sum of the cross-sectional areas of individual wires in a wire rope or strand.
Becket Loop: A loop of small rope or a strand of rope fastened to the end of a large wire rope to facilitate installation.
Bending Stress: Stress on wires of a wire rope imposed by bending. This stress need not be added to direct load stresses. When sheaves and drums are of suitable size, bending stress does not affect the normal life of the wire rope.
Birdcage: A colloquialism describing the appearance of a wire rope that is forced into compression. The outer strands form a "cage" and at times displace the core. rope in an isolated area in the opposite direction of the rope lay, causing it to take on the appearance of a birdcage.
Brake: A device used for slowing or stopping motion by friction or electromagnetic means.
Brake, drag: A brake that provides stopping force without external control.
Brake, holding: A brake that sets automatically and that prevents motion when power is off.
Brake, parking: A device to prevent the movement of a stationary vehicle.
Breaking strength: The measured load required to break a wire rope or chain.
Bridle sling: A sling composed of multiple legs (branches), the top ends of which terminate in a fitting that latches onto the lifting hook.
Bull Ring: The main large ring of a sling to which sling legs are attached.
Cable: A term loosely applied to wire ropes, wire strands, manila ropes, and electrical conductors.
Cable laid wire rope: A type of wire rope consisting of several independent wire ropes laid into a single wire rope.
Center: A single wire or fiber in the center of a strand around which the wires are laid.
Choker rope: A short wire-rope sling used to form a slip noose around the object to be moved or lifted
Circumference: Measured perimeter of a circle circumscribing the wires of a strand or the strands of a wire rope.
Clamp, strand: A fitting used to form a loop at the end of a length of strand; consists of two grooved plates and bolts.
Clevis: A U-shaped fitting with pins.
Clip: A fitting used to clamp two parts of wire rope.
Come-along: A portable, hand-operated device consisting of a housing, a length of chain or wire rope, two hooks, and a ratcheting lever, that is used for miscellaneous pulling
Core: The center member of a wire rope around which the strands are laid. It may be fiber, a wire strand, or an independent wire rope.
Corrosion: Chemical decomposition by exposure to moisture, acids, alkalis, or other destructive agents.
Cover wires: The outer layer of wires.
Crane: A machine used for lifting and lowering a load vertically and moving it horizontally and that has a hoisting mechanism as an integral part of it.
Critical item: A part, assembly, component, or piece of equipment designated as that could jeopardize future operation or the safety of the facility
Critical Service: The use of equipment or tackle for hoisting, rigging, or handling of critical items.
Deceleration Stress: Additional stress imposed on a wire rope due to decreasing the load velocity.
Deflection: Sag of a rope in a span, usually measured at midspan as the depth from a chord joining the tops of the two supports. Any deviation from a straight line.
Design factor: Ratio of ultimate strength to the design working stress.
Diameter: Distance measured across the center of a circle circumscribing the wires of a strand or the strands of a wire rope. in which a malfunction could occur.
Fatigue: The tendency of a material to break under repeated stress.
Elastic Limit: Limit of stress beyond which a permanent deformation takes place within the material. This limit is approximately 55-65 percent of breaking strength of steel-wire ropes.
Equalizer: A device used to compensate for unequal length or stretch of a hoist rope.
Equalizing Slings: Slings composed of wire rope and equalizing fittings.
Fiber Centers: Cords or rope made of vegetable fiber used in the center of a strand.
Fiber Cores: Cords or rope made of vegetable fiber used in the core of a wire rope.
Flat Rope: Wire rope made of parallel alternating right-lay and left-lay ropes sewn together by relatively soft wires.
Flattened strand rope: A wire rope with either oval or triangular strands that present a flattened rope surface.
Galvanize: To coat with zinc to protect against corrosion.
Galvanized Rope: Rope made of galvanized wire.
Galvanized Strand: Strand made of galvanized wire.
Galvanized wire: Wire coated with zinc
Guy line: Strand or rope, usually galvanized, for holding a structure in position.
Hoist: A device that applies a force for lifting or lowering. Hoist, lever operated: A lever-operated manual device used to lift, lower or pull a load and to apply or release tension.
Idler: Sheave or roller used to guide or support a rope.
Internally lubricated: Wire rope or strand having all wires coated with lubricant.
Kink: Permanent distortion of wires and strands resulting from sharp bends. of rope or a strand.
Lay length: The lengthwise distance on a wire rope in which a strand makes one complete turn around the rope's axis
Line: A rope used for supporting and controlling a suspended load.
Load: The total weight superimposed on the load block or hook.
Load Block: The assembly of hook or shackle, swivel, bearing, sheaves, pins, and frame suspended by the hoisting ropes.
Load bearing parts: Any part of a material-handling device in which the induced stress is influenced by the hook load. A primary load-bearing part is a part the failure of which could result in dropping, upset, or uncontrolled motion of the load. Load-bearing parts which, if failed, would result in no more than stoppage of the equipment without causing dropping, upset, or loss of control of the load are not considered to be primary load-bearing parts.
Main Hoist: The hoist mechanism provided for lifting the maximum-rated load.
Modulus of Elasticity: Mathematical quantity giving the ratio, within the elastic limit, between a definite range of unit stress on a wire rope and the corresponding elongation.
Nondestructive examination (NDE): The development and application of technical methods to examine materials or components, in ways that do not impair future usefulness and serviceability, in order to detect, locate, measure, and evaluate discontinuities, defects, and other imperfections; to assess integrity, properties, and composition; and to measure geometrical characteristics.
Pallet Truck: A self-loading, nonmotorized or motorized low-lift truck equipped with wheeled forks of dimensions sized to go between the top and bottom boards of a double-faced pallet, the wheels fitting into spaces between the bottom boards, so as to raise the pallet off the floor for transporting
Peening: Permanent distortion of outside wire in a rope caused by pounding. Preformed wire rope: Wire rope in which the strands are permanently shaped, before being fabricated into the rope, to the helical form they assume in the wire rope.
Preformed strand: Strand in which the wires are permanently shaped, before being fabricated into the strands, to the helical form they assume in the strand.
Prestressing: Stressing a wire rope or strand before use under such a tension and for such a time that stretch that would otherwise occur once the load is picked up is largely nonexistent.
Proof Test: A nondestructive tension test performed to verify construction and workmanship of slings or rigging accessories.
Rated Capacity: The maximum hook load that a piece of hoisting equipment is designed to carry; also the maximum load that an industrial truck or a sling, hook, shackle, or other rigging tackle is designed to carry.. NOTE: At the option of the user, a rated capacity can be assigned that is less than the design-rated capacity.
Rigging: The hardware or equipment used to safely attach a load to a lifting device. The art or process of safely attaching a load to a hook by means of adequately rated and properly applied slings and related hardware.
Safe Working Load: Load that a rope may carry economically and safely.
Shackle: A type of clevis normally used for lifting .
Side Pull: That portion of a hoist pull acting horizontally when the hoist lines are not operated vertically
Slings: Wire ropes, chains, synthetic web, and metal mesh made into forms, with or without fittings, for handling loads.
Span: The horizontal, center-to-center distance of runway rails. Strand: An arrangement of wires helically laid about an axis or another wire or fiber center to produce a symmetrical section.
Switch, limit: A switch that is operated by some part or motion of a power-driven machine or equipment to alter the electrical circuit associated with the machine or equipment.
Turnbuckle: A device attached to wire rope for making limited adjustments in length. It consists of a barrel and right- and left-hand threaded bolts.
Wire rope: Wire strands laid helically around an axis or a core.
Wire (round): Single continuous length of metal, cold drawn from a rod.
Wire (shaped): A single continuous length of metal either cold drawn or cold rolled from a rod.
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