Safe Work Procedure: Opening an HSI Crusher

Document Number: [SWP-NUMBER] Revision Date: [DATE] Next Review Date: [NEXT REVIEW DATE] Department: [DEPARTMENT NAME]

1. Scope

This Safe Work Procedure (SWP) outlines the necessary safety precautions and procedures to be followed when opening a Horizontal Shaft Impactor (HSI) crusher for inspection, maintenance, or clearing blockages. It applies to all personnel involved in the task. This procedure covers steps to safely access the crusher's internal components, identify potential hazards, and implement control measures to minimize risks.

2. Definitions

HSI Crusher: A Horizontal Shaft Impactor crusher is a machine designed to reduce the size of materials by using impact force.

Lockout/Tagout (LOTO): A safety procedure used to ensure that dangerous machines are properly shut off and not able to be started up again prior to the completion of maintenance or servicing work [1].

Personal Protective Equipment (PPE): Equipment worn to minimize exposure to hazards that cause serious workplace injuries and illnesses [2].

3. Responsibilities

3.1 Supervisors

Ensure that all workers are properly trained and competent to perform the task.
Conduct pre-job briefings to discuss potential hazards and control measures.
Ensure that all equipment is in good working order and that all safety devices are functioning properly.
Enforce adherence to this SWP and all other relevant safety procedures.

3.2 Workers

Follow all instructions and procedures outlined in this SWP.
Participate in pre-job briefings and hazard assessments.
Use required PPE properly and maintain it in good condition [2].
Report any hazards or unsafe conditions to the supervisor immediately.
Do not operate equipment unless properly trained and authorized.

3.3 Health and Safety Representative

Assist in the development and review of this SWP.
Monitor workplace conditions to ensure compliance with safety standards.
Investigate incidents and recommend corrective actions.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Dust Exposure	Respiratory irritation, eye irritation, potential long-term respiratory issues	Use adequate ventilation, wear a NIOSH-approved N-95 dust mask, and use water sprays to suppress dust 5, 14.
Fall from height	Injury, Fractures	Use fall protection equipment such as safety harnesses and lanyards when working at heights. Ensure proper scaffolding or elevated work platforms are in place.
Stored Energy	Serious injury or death	Implement Lockout/Tagout (LOTO) procedures to de-energize and isolate the crusher before opening it [1].
Moving Parts	Amputation, crushing injuries	Ensure all moving parts are completely stopped and locked out before accessing the crusher's internal components.
Sharp Edges and Protrusions	Cuts, lacerations	Wear appropriate gloves and use caution when handling components with sharp edges.
Confined Space	Asphyxiation, entrapment	If the crusher's internal area meets the definition of a confined space, follow confined space entry procedures, including air monitoring and rescue planning.
Hazardous Materials	Skin irritation, chemical burns, respiratory issues	Review Safety Data Sheets (SDS) for any hazardous materials present. Use appropriate PPE, including gloves and eye protection [3].
Unexpected start-up	Serious Injury or Death	Verify the crusher is de-energized and locked out before commencing work.

5. Personal Protective Equipment (PPE)

Always use the appropriate PPE for the task to minimize exposure to hazards [2].

Safety Glasses/Goggles: To protect eyes from dust, debris, and chemical splashes 4, 5.
Hard Hat: To protect the head from falling objects and impacts.
Gloves: Wear impervious gloves, such as nitrile, to protect hands from sharp edges, chemicals, and abrasion 5, 6.
Safety Boots: To provide foot protection against impacts, punctures, and crushing hazards.
Hearing Protection: Use earplugs or earmuffs in noisy environments.
Respiratory Protection: Wear a NIOSH-approved N-95 dust mask in areas with high dust concentrations [4].
Protective Clothing: Wear suitable protective clothing to prevent skin contact with dust and other materials 4, 6.

Inspect all PPE before use for damage or defects. Replace damaged PPE immediately.

6. Equipment and Tools

Lockout/Tagout (LOTO) Devices: Locks, tags, and other devices to isolate energy sources.
Hand Tools: Wrenches, screwdrivers, pliers, etc., for disassembly and maintenance.
Lifting Equipment: Cranes, hoists, or jacks for handling heavy components.
Tag line: To help guide suspended loads.
Air Monitoring Equipment: To test for hazardous atmospheres in confined spaces.
Cleaning Equipment: Shovels, brooms, and vacuum cleaners for removing debris.

Inspect all equipment and tools before use to ensure they are in good working condition. Remove any defective equipment from service.

7. Pre-Job Requirements

7.1 Training and Competency

All personnel involved in opening the HSI crusher must be trained and competent in the following areas:
- Lockout/Tagout procedures
- Hazard identification and risk assessment
- Proper use of PPE
- Safe use of tools and equipment
- Confined space entry procedures (if applicable)

7.2 Pre-Job Briefing

Conduct a pre-job briefing with all personnel involved to discuss the following:
- Scope of the work
- Potential hazards and risks
- Control measures to be implemented
- Emergency procedures
- Roles and responsibilities

7.3 Work Area Preparation

Ensure the work area is clear of obstructions and slip/trip hazards.
Barricade the area to prevent unauthorized access.
Provide adequate lighting.
Ensure proper ventilation to minimize dust exposure [5].
Make sure all the needed tools are available.

8. Safe Work Procedure Steps

8.1 Lockout/Tagout (LOTO)

Step 1: Identify all energy sources for the HSI crusher (electrical, mechanical, hydraulic, etc.).
Step 2: Notify all affected personnel that the crusher will be shut down and locked out.
Step 3: Shut down the crusher according to the manufacturer's instructions.
Step 4: Isolate all energy sources by disconnecting, closing, or blocking them.
Step 5: Apply LOTO devices to each energy-isolating device.
Step 6: Verify that the crusher is de-energized by attempting to start it up. Ensure that no moving parts are active.

Safety Consideration: Double-check that all energy sources are properly isolated and locked out before proceeding.

8.2 Opening the Crusher

Step 1: Ensure the crusher has been properly locked out and tagged out.
Step 2: Use appropriate tools to loosen and remove access panels or doors.
Step 3: If access panels are heavy, use lifting equipment to safely remove them.
Step 4: Ensure that the area around the opening is clear of any personnel.
Step 5: Carefully open the crusher, being aware of any potential material buildup or blockages.

Safety Consideration: Be aware of potential material buildup that could fall out when the crusher is opened.

8.3 Inspection and Maintenance

Step 1: Conduct a thorough inspection of the crusher's internal components.
Step 2: Identify any areas that require maintenance or repair.
Step 3: If clearing blockages, use appropriate tools and techniques to safely remove the material.
Step 4: Ensure proper ventilation and respiratory protection during cleaning and maintenance 5, 14.

Safety Consideration: Be aware of sharp edges and protrusions inside the crusher. Wear gloves to protect your hands 5, 6.

8.4 Closing the Crusher

Step 1: Ensure all tools and equipment have been removed from inside the crusher.
Step 2: Replace access panels or doors and secure them properly.
Step 3: Verify that all safety devices are in place and functioning correctly.

Safety Consideration: Ensure that all components are correctly reinstalled before closing the crusher.

8.5 Removing Lockout/Tagout (LOTO)

Step 1: Inspect the work area to ensure that all tools, materials, and personnel are clear of the crusher.
Step 2: Remove LOTO devices, following the established LOTO procedure.
Step 3: Notify affected personnel that the crusher is ready to be restarted.
Step 4: Restart the crusher according to the manufacturer's instructions.

Safety Consideration: Ensure that all personnel are clear of the crusher before restarting it.

9. Precautions and Safety Measures

Lockout/Tagout: Always follow proper LOTO procedures before opening the crusher.
Confined Space Entry: If the crusher's internal area meets the definition of a confined space, follow all confined space entry procedures.
Dust Control: Use water sprays and ventilation to minimize dust exposure 5, 14.
PPE: Always wear appropriate PPE, including safety glasses, gloves, and respiratory protection 4, 5, 6, 14.
Housekeeping: Keep the work area clean and free of obstructions.

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, immediately stop work and assess the situation.
Evacuate the area if necessary.
Provide first aid to any injured personnel.
Contact emergency services if required.

10.2 Specific Emergency Scenarios

Dust Inhalation: Move to an area with fresh air. Seek medical attention if breathing difficulties persist.
Chemical Exposure: Flush affected area with water for at least 15 minutes. Seek medical attention.
Entrapment: Immediately stop the crusher and initiate rescue procedures.

10.3 Emergency Contact Information

[Emergency Contact 1] - [Phone Number]
[Emergency Contact 2] - [Phone Number]
[Emergency Services] - 911

11. Incident Reporting and Investigation

Report all incidents, near-misses, and hazards to the supervisor immediately. Conduct a thorough investigation to determine the root cause of the incident and implement corrective actions to prevent recurrence.

Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]