An Analysis of Manual Ice/Frozen Sand Block Clearing Risks in Company XYZ Hoppers

Abstract

The purpose of this study was to analyze the manual ice/frozen sand block clearing process for Company XYZ’s hoppers. This study was prompted by an observed absence of standard operating procedures, lack of specific machine lock-out tag-out steps for the removal of ice/frozen sand blocks within the hoppers, and inconsistency in adequate tool usage. The goals for the study were to determine the potential risk levels for an employee required to conduct ice/frozen block clearing activities for both wet and dry plant operations, to assess the organizations current ice/frozen sand block clearing procedures and evaluate current general lock-out tag-out procedures. To achieve the goals of this study, formal risk assessments were performed on ice/frozen sand block clearing activities. A review was performed on the current hopper unplugging procedures and a lock-out tag-out compliance checklist was used to evaluate Company XYZ’s hazardous energy control program. The collected data indicated that at least 17 moderate to high-risk activities existed in regard to clearing plugged hoppers of ice/frozen sand blocks. It was determined that no documented formal procedure existed. In addition, the analyzed current lock-out tag-out procedures were deemed to be too general from a hazardous energy source control standpoint. The recommendations for Company XYZ’s management include the development of a multi-disciplinary task force to abate the identified employee safety and health hazards, to develop a formalized procedure for the clearing process from hoppers, and to embark on a systematic process whereby machine specific lock-out tag-out practices are instituted throughout the facilities.