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Occupational safety instructions for sharpeners. Full document

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General requirements for labor protection

1.1. This instruction has been developed in accordance with the Interindustry Rules for Occupational Health and Safety during cold metal working POT R M-006-97 and is intended for workers of all professions who use sharpening machines and machines for sharpening cutters and tools. Further, all workers working on sharpening machines in these instructions are referred to as sharpeners.

1.2. It is allowed to sharpen tools on a sharpening machine and machines for sharpening cutters and tools. A CBN wheel can be installed on the machine for finishing the cutting tool.

1.3. The following persons are allowed to work on grinding machines:

• not younger than 18 years old;
• passed a medical examination;
• trained in safe methods and techniques of work according to an approved program, who know the operating instructions for the machine, have acquired the necessary practical skills for servicing and working on the machine and have passed the exam;
• having a certificate in the profession of a sharpener, grinder, etc.;
• have undergone introductory training on labor protection and on-the-job training.

1.4. The sharpener must:

• comply with the requirements of these instructions and the machine operating certificate;
• do not allow unauthorized persons into the workplace and do not transfer control of the machine to other workers without the permission of the foreman;
• inform the foreman about malfunctions that make it impossible to continue safe work, and do not begin work until they are eliminated.

1.5. On the territory of the plant and in the workshops, follow these rules:

• internal labor regulations, observe the regime of work and rest;
• walk on sidewalks and paths specially designed for pedestrian traffic, and where there are none, on the carriageway, keeping to the left;
• be attentive to the signals of moving vehicles and do not run across the path in front of it;
• do not walk on railway tracks; do not stand or walk under or in close proximity to a raised load;
• do not look at electric welding with unprotected eyes;
• Beware of gas poisoning, do not stay idle near gas pipelines, acetylene apparatus and other devices where gas may be released;
• do not touch electrical wires or other current-carrying parts, do not try to fix the malfunction of electrical wires or electrical equipment yourself, call an electrician for this purpose;
• do not turn on or off (except in emergency cases) machines, machines and mechanisms, the work of which is not assigned to you by the administration;
• driving electric cars is prohibited;
• do not open the doors of electrical panels and other electrical equipment;
• do not lift the load beyond the permissible norm.

Remember that it is allowed to lift a load weighing no more than:

• men - 50 kg;

women aged 18 and over:

• lifting and moving weights when alternating with other work (up to 2 times per hour) - 10 kg,
• lifting and moving weights constantly during a work shift - 7 kg;

the amount of dynamic work performed during each hour of a work shift should not exceed:

• from the working surface - 1750 kgm,
• from the floor - 875 kgm;
• lifting weights to a height of more than 1,5 m - 10 kg;
• when moving goods on trolleys or in containers, the applied force should not exceed 10 kg.

The mass of the lifted and moved cargo includes the mass of tare and packaging.

1.7. Harmful and dangerous production factors when working on sharpening machines:

• danger of injury to the sharpener and others from the rupture of an abrasive and CBN tool rotating at a high peripheral speed (up to 120 m/s);
• significant dust formation in the cutting zone when the wheel is operated without coolant, which can lead to eye injury and cause respiratory disease;
• danger of electric shock.
• sharp edges, burrs and roughness on the surfaces of equipment, tools, parts.

To preserve the health of an employee, the maximum allowable concentration (MPC) and the maximum allowable level (MPL) of physical factors that are most characteristic at the workplace of an employee of this profession:

• noise (equivalent sound level) 80 dB;
• illumination of the working surface 400 lx;
• air temperature:
• summer 18-27°C
• winter 17-23°C;
• dust content 6,0 mg/m3.

1.7. To perform the work, the sharpener is provided with the following personal protective equipment:

• costume;
• combined gloves;
• goggles;
• respirator.

1.8. For fire safety purposes, keep your work area clean. Smoke only in a designated area. Put used rags in a special box.

1.9. If you have any accident, immediately notify the foreman or workshop manager and go to the health center.

1.10. The sharpener must know the rules for providing first (pre-medical) aid to victims of electric current, fire and other traumatic factors, according to IOT-149 “Instructions for providing first aid to victims.”

1.11. Observe personal hygiene measures:

• do not wash your hands in oil, emulsion, kerosene;
• do not dry your hands with the ends contaminated with shavings;
• do not eat at the workplace;
• do not store personal clothing in the workplace.

1.12. The requirements of this manual are mandatory. Failure to comply with these requirements is considered as a violation of labor and production discipline.

2. Labor protection requirements before starting work

2.1. Before starting work, the sharpener must put on overalls and personal protective equipment, as provided for in the Standard Industry Standards, and tuck hair under the headgear. Overalls must be fastened with all buttons; there should be no loose or torn parts of clothing. If there are no transparent special protective screens on the machine, wear safety glasses.

2.2. Bring the workplace to a safe state: remove foreign objects, place the issued tool for sharpening on a bedside table or rack without cluttering the workplace, clear passages, adjust the lighting of the machine and work area so that the lighting is sufficient, but does not blind the eyes.

2.3. Check for availability and serviceability:

• fencing of drive belts, current-carrying parts of electrical equipment;
• grounding devices;
• safety devices to protect the material being processed from flying particles of the grinding wheel;
• dust extraction devices and whether they are correctly installed in the best position for collecting dust.
• blocking devices;
• fork protection of the elbor circle (if the elbor circle is installed);
• auxiliary tools and devices;
• handrests or other devices for stopping the workpieces;
• lattice wooden flooring near the machine.

2.4. Inspect the guards and make sure that:

• casings and removable covers are fixed securely;
• movable safety visors move freely and are securely fixed in different positions;
• the opening angle of the casings for machines that have a fence with adjustable visors is the smallest;
• the opening angle of the casings without safety visors above the horizontal plane passing through the axis of the machine spindle complies with the standards;
• The gap between the circle and the upper edge of the opening of the movable casing, as well as between the circle and the safety visor, is no more than 6 mm.

2.5. To support parts that are fed to the grinding wheel manually, use supports and securely fasten them, installing them so that:

• the gap between the tool rest and the working surface of the grinding wheel was less than half the thickness of the part being sanded, but not more than 3 mm;
• the upper point of contact of the part with the grinding wheel was above the horizontal plane passing through the center of the wheel, but not more than 10 mm;
• assistants must meet the following requirements:
• be mobile, providing the ability to install and secure them in the required position;
• have a sufficiently large area for a stable position of the workpiece;
• have a flat working surface, the edges of which on the side of the grinding wheel should be free of gouges, chips and other defects.

2.6. Before turning on the machine, check:

• absence of potholes and cracks on the grinding wheel, and for the CBN wheel, absence of peeling of the CBN-containing layer;
• the presence of a gasket between the clamping flanges and the circle,
• reliability of fastening nuts clamping the flanges, as well as centering the circle.
• make sure there are no people around the machine.

It is FORBIDDEN to use circles with cracks or potholes.

2.7. Test the machine at idle speed for 3-5 minutes, being away from the danger zone of possible scattering of pieces of a ruptured circle.

2.8. Make sure that the machine controls are in good working order and that there is no radial or axial runout of the wheel.

3. Labor protection requirements during work

3.1. Bring the part to the circle gradually, without jerking or sharp pressure, protecting the circle from blows and jolts. It is not allowed to use levers to increase pressure on the circle. When processing a part, stand to the side, not in the plane of rotation of the wheel, using a wooden lattice ladder, the size of which should be sufficient for free movement on it during operation and maintenance of the machine.

3.2. Keep the gap between the support and the circle no more than 3 mm and the gap between the safety visor and the circle no more than 6 mm. As the circle operates, lower the visor and reinstall the rest. In this case, the machine must be turned off and the wheels stopped.

3.3. Avoid roughing and cleaning work with the side surfaces of the grinding wheel. When sharpening the tool with the side surfaces, make sure that the protective flanges do not touch the tool. When finishing a tool on a CBN wheel, it is prohibited to use the side surfaces of the wheel.

3.4. When processing short or thin products, do not work with gloves or hold the product in your hands, but use special tools and clamps. Place the workpieces on the tool rest firmly and press them tightly against it. Hold a long product, for example, rod material, at the side of the body. Sharpening knives is allowed only on special sharpening machines.

3.5. Do not pass or receive anything through the machine while it is in operation. It is not allowed to place tools, parts or other objects on the machine.

3.6. Monitor wheel wear. If there are two circles on one machine spindle, their uneven operation is not allowed. The difference in their diameters should not exceed 25%. The smallest diameter of the circle when it is worn must be at least the diameter of the flange + 20 mm.

3.7. When dressing a grinding wheel, you should:

• check the reliability of fastening the circle;
• use special editing tools (diamond pencils, metal rollers or stars);
• while the worker is away from the plane of rotation of the circle.

3.8. To remove abrasive and metal dust, use a broom brush; perform this operation wearing safety glasses and with the rotation of the wheels completely stopped. It is not allowed to touch the grinding wheel with your hands until it stops completely and do not slow down the wheel with any objects.

3.9. It is necessary to turn off and stop the machine when:

• leaving the machine even for a short time;
• temporary cessation of work;
• interruption in the supply of electricity;
• detection of electrical voltage on parts of the machine;
• the occurrence of strong vibration of the grinding wheel or machine;
• detection of malfunctions in the equipment;
• loosening bolts, nuts and other connecting parts of the machine;
• cleaning, lubricating, cleaning the machine;
• exfoliation of the elboron-containing layer.

3.10. It is not allowed to clutter up workplaces and free passages.

3.11. It is prohibited to work on a faulty machine. The machine is considered faulty if:

• the emery wheel guard is missing or not securely fixed;
• missing, broken or unreliably fixed grounding of the machine;
• there is no supporting table (hand rest) or the gap between the table and the working surface of the circle exceeds 3 mm;
• The sanding wheel has runout. Runout may occur due to incorrect installation of the wheel or its uneven production;
• there is no protective screen to protect the eyes from small fragments of stone and metal filings;
• the emery stone has chipping or cracks.

3.12. On the grinding machine it is prohibited:

• work without glasses or a protective screen;
• work in gloves;
• process parts with a lateral (flat) surface of the circle;
• strike the emery stone (circle);
• stand in front of the emery stone (circle) while the machine is operating or processing a part;
• press the workpiece too hard on the wheel, slowing down its rotation;
• work in clothes with developing ends (robe strings, robe hems, belt, etc.);
• lean close to the emery stone (circle);
• undress and dress near the machine;
• clean, lubricate and repair the included machine;
• machine bulky parts;
• be distracted during work;
• work without a wooden ladder.

3.13. When transporting abrasive tools to the machine, it is necessary to use trolleys.

3.14. Immediately before installing the wheel on the machine, the wheel should be carefully inspected and checked for cracks by lightly tapping it with a wooden hammer. The gap between the machine spindle (motor shaft) and the internal hole in the circle should be within 0,1-0,3 mm.

3.15. The wheel must be secured to the spindle using clamping flanges, the diameter of which should be 1/3 of the outer diameter of the wheel. Gaskets made of cardboard, rubber or leather with a thickness of 0,6 mm should be placed between the flanges and the circle. The diameter of the gasket must be larger than the diameter of the flanges and the gasket must protrude beyond the flanges along the entire circumference by at least 1 mm.

3.16. When fastening the circle, tighten the nuts only with a wrench; the use of amplifiers and impact tools is prohibited.

3.17. The circle must be protected by a protective casing. If the opening angle of the fixed protective casing is located above the horizontal plane passing through the axis of the wheel, then the casing must be equipped with a safety movable visor, which serves to reduce the opening angle of the casing when the wheel wears out. The gap between the new circle and the inner cylindrical surface of the casing should be within 3-5% of the diameter of the circle, but not less than 3 mm for circles less than 10 cm and no more than 2,5 cm for circles over 50 cm. The gap between the circle and the side walls the casing should be within 1,0-1,5 cm. The removable cover of the casing during operation should be tightly pressed into its fixed part with a reliable fastening.

3.18. Circles 15 cm and above must be balanced on a special device before installation on the machine. The wheel must be balanced together with the protective flanges.

3.19. Each wheel after its installation on the machine must be started at idle speed at the operating speed for 5 minutes with the obligatory presence of a protective casing. Each wheel after its installation on the machine must be straightened with a special tool. The wheel adjustment must be repeated periodically.

3.20. Each machine (near the machine) must have a sign indicating the number of spindle revolutions and the maximum permissible wheel sizes.

3.21. When working on a sharpening machine, tool sharpening can only be done on those machines on which this is provided for by the technology. It must be secured in appropriate devices. It is prohibited to hold the instrument suspended by hand;

3.1. When sharpening axial tools on centers, you must ensure that the center holes are in good working order. Centers should not have worn tapers.

Do not tighten a tool with defective center holes.

4. Labor protection requirements in emergency situations

4.1. In the event of a sudden breakdown of the machine, device, or abrasive wheel, immediately turn off and de-energize the machine.

4.2. If there is a power outage, turn off the machine. After eliminating the fault, continue working.

4.3. If the fuses on the electrical equipment of the machine burn out, notify the foreman or workshop mechanic.

4.4. If voltage is detected on the metal parts of the machine (sensation of current), the electric motor operates in two phases (hums), the grounding wire is broken - immediately stop the machine, report the fault to the foreman about the electrical equipment malfunction and do not start work without his instructions.

4.5. In case of fire:

• de-energize electrical equipment;
• immediately notify all workers and the foreman, call the fire department at _______ or inform the plant dispatcher at _______;
• take measures to call the direct manager of the workshop, section or other officials to the place of fire;
• start extinguishing the fire with available fire extinguishing equipment before the arrival of the fire brigade. Remember that when extinguishing electrical equipment with carbon dioxide, powder fire extinguishers or sand, keep a safe distance (at least 1 m) from the spray nozzle and the fire extinguisher body to live parts.

Remember that fired electrical equipment must be extinguished with carbon dioxide, powder fire extinguishers, as well as sand, flared oil, kerosene - with an OXO-10 fire extinguisher.

4.6. In the event of an accident, first of all, free the victim from the traumatic factor and provide first aid in accordance with the “Instructions for providing first aid to victims.”

ATTENTION: when releasing the victim from the action of electric current, be careful not to come into contact with the live part.

Notify the foreman or shop manager of the accident.

5. Labor protection requirements at the end of work

5.1. Switch off and disconnect the machine.

5.2. Remove the machine, remove abrasive dust and dirt, and lubricate the machine guides.

5.3. Tidy up your tools and work area.

5.4. Report any problems and shortcomings identified during work to the shift worker and the foreman.

5.5. Wash your hands and face with warm soapy water or take a shower.

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