TechFire 225 Safety Manual
Contents
1. disconnected A short wire or positive locking device attaching the air hose to the tool must also be used and will serve as an added safeguard If an air hose is more than 1 2 inch 12 7 millimeters in diameter a safety excess flow valve must be installed at the source of the air supply to reduce pressure in case of hose failure In general the same precautions should be taken with an air hose that are recommended for electric cords because the hose is subject to the same kind of damage or accidental striking and because it also presents tripping hazards When using pneumatic tools a safety clip or retainer must be installed to prevent attachments such as chisels on a chipping hammer from being ejected during tool operation Pneumatic tools that shoot nails rivets staples or similar fasteners and operate at pressures more than 100 pounds per square inch 6 890 kPa must be equipped with a special device to keep fasteners from being ejected unless the muzzle is pressed against the work surface Airless spray guns that atomize paints and fluids at pressures of 1 000 pounds or more per square inch 6 890 kPa must be equipped with automatic or visible manual safety devices that will prevent pulling the trigger until the safety device is manually released HYDRAULIC POWER TOOLS The fluid used in hydraulic power tools must be an approved fire resistant fluid and must retain its operating characteristics at the most extreme temperatures to which it2. of the shop for special work inspected when sent out and inspected when returned and 3 for jacks subjected to abnormal loads or shock inspected before use and immediately thereafter SAFETY PROCEDURE 3 Proper Use of Electrical Devices Parts of this procedure are copied from the document FIRST Robotics Competition TEAM SAFETY MANUAL page 10 Proper use and respect for electricity is paramount The following are general guidelines for ensuring basic electrical safety requirements are met e Only use appliances and cords that have been approved by recognized authorities such as Underwriters Laboratories UL or ETL Examples of the markings to look for are i Liste e Inspect your equipment cords and extension cords routinely to ensure they are in good condition Conditions to look for include o Cracked torn or worn insulation o Corroded prongs o Missing or damaged prongs UNACCEPTABLE e e DO NOT overload electrical fixtures and or receptacles UNACCEPTABLE ay O photos from Grays Harbor PUD Aberdeen WA e Avoid the following electrical power supply setups to prevent overloading o Power strip plugged into another power strip Extension cord plugged into another extension cord Extension cord plugged into a power strip Multi device receptacle plugged into a power strip or extension cord USE THE CORRECT SIZE EXTENSION CORD as detailed below oO 0 0 Sizing an Extension Cord from h
3. stable and undamaged wheel when tapped will give a clear metallic tone or ring To prevent an abrasive wheel from cracking it must fit freely on the spindle The spindle nut must be tightened enough to hold the wheel in place without distorting the flange Always follow the manufacturer s recommendations Take care to ensure that the spindle speed of the machine will not exceed the maximum operating speed marked on the wheel An abrasive wheel may disintegrate or explode during start up Allow the tool to come up to operating speed prior to grinding or cutting The employee should never stand in the plane of rotation of the wheel as it accelerates to full operating speed Portable grinding tools need to be equipped with safety guards to protect workers not only from the moving wheel surface but also from flying fragments in case of wheel breakage When using a powered grinder e Always use eye or face protection e Turn off the power when not in use e Never clamp a hand held grinder in a vise PNEUMATIC TOOLS Pneumatic tools are powered by compressed air and include chippers drills hammers and sanders There are several dangers associated with the use of pneumatic tools First and foremost is the danger of getting hit by one of the tool s attachments or by some kind of fastener the worker is using with the tool Pneumatic tools must be checked to see that the tools are fastened securely to the air hose to prevent them from becoming
4. When soldering observe the following points e NEW At FIRST events Use lead free solder only and solder with electrically heated soldering iron gun only No torches or open flames of any kind are allowed in the buildings Wear eye and face protection Solder in well ventilated areas Never touch the iron gun It heats to extreme temperatures that will cause severe burns Prevent burns Wear cotton clothing that covers your arms and legs Always wash your hands with soap and water after handling solder Work on a fire resistant surface Keep your soldering iron in its protective holder when not actually being used Do not leave any hot tools such as a hot drill bit where someone can accidentally contact the hot element SAFETY PROCEDURE 4 Tagout Procedure Any device that is faulty such that it can cause injury to anyone if used in the faulty condition shall be removed from service Items that cannot be removed immediately from the build areas require a Lockout tag to be installed The Lockout tag is similar to that shown below a GANGER DO NOT emmm OPERATE Siiri by Dait SEE OTHER SIME The tag must be filled out by either a Student Safety Captain mentor or facility maintenance person The information required is Name of device being locked out Brief description of device fault Lockout date Name of person performing the Lockout Each tag shall be numbered sequentially and the Lockout information mus
5. charging area clean and orderly Place your battery charger in an area where cooling air can freely circulate around the charger Battery chargers can fail without proper ventilation Do not short out the battery terminals If metal tools parts contact the terminals simultaneously it will create a direct short circuit This may cause high heat to develop in the battery terminal part tool area and the battery could explode If a quick disconnect is not available and you must use tools to disconnect the battery make sure metal tools don t contact both terminals at the same time Ongoing Battery Inspection Periodically inspect your battery for any evidence of damage such as a cracked case or leaking electrolyte Bent terminals can also be a potential leak source After each competition round inspect the battery Check your battery prior to competing in each round APPENDIX B FORMS PARTICIPANT TRAINING RECORD FORM FIRST FRC Team 225 Participant name Initial Training Season 2011 Procedure Description Training Date Certified by Title 1 2 3 Re Training Procedure Reason for Re training Training Date Certified by Title Inspector Inspection Date Build Area SAFETY INSPECTION FORM FIRST FRC Team 225 Season 2011 Procedure Safety Violations Corrective Actions Taken Certifi
6. each participant are to be kept and maintained by the Student Safety Captain The Participant Training Record Form is given in Appendix B INSPECTION AUDITING Home Base Construction Area The Home Base Construction areas should be inspected at least once during any day participants are using them The areas include robot build area machine shop team classroom area practice field The inspection must be logged on a Team 225 Safety Inspection Form and filed appropriately in the Safety Manual Binder A separate form shall be filled out for each area inspected and the inspector shall sign the bottom of each form Competition Pit Area Competition Pit Areas shall be inspected each morning before the team starts working on the robot The inspection must be logged on a Team 225 Safety Inspection Form and filed appropriately in the Safety Manual Binder Authorized Inspectors Persons authorized to perform official safety inspections are in order of preference Student Safety Co Captains Safety Mentor Student participants specifically named by the Safety Mentor or Team President All other Mentors P Dan inspection form shall be initialed by a mentor or Team President Safety Violation Reporting and Corrective Actions When a Safety violation is noted whether during a regular inspection or during the normal course of the working time it should be recorded on a Team 225 Safety Inspection Form and filed in chronological order with
7. ears and scroll saws and jigsaws saber and scroll saws with blade shanks a nominal 1 4 inch 6 35 millimeters or less in diameter It is recommended that the constant pressure control switch be regarded as the preferred device Other hand held power tools such as circular saws having a blade diameter greater than 2 inches 5 08 centimeters chain saws and percussion tools with no means of holding accessories securely must be equipped with a constant pressure switch ELECTRIC TOOLS Participants using electric tools must be aware of several dangers Among the most serious hazards are electrical burns and shocks Electrical shocks which can lead to injuries such as heart failure and burns are among the major hazards associated with electric powered tools Under certain conditions even a small amount of electric current can result in fibrillation of the heart and death An electric shock also can cause the user to fall off a ladder or other elevated work surface and be injured due to the fall To protect the user from shock and burns electric tools must have a three wire cord with a ground and be plugged into a grounded receptacle be double insulated or be powered by a low voltage isolation transformer Three wire cords contain two current carrying conductors and a grounding conductor Any time an adapter is used to accommodate a two hole receptacle the adapter wire must be attached to a known ground The third prong must never be removed fro
8. ed by Date Corrected 1 EQUIPMENT LOCKOUT FORM FIRST FRC Team 225 Season 2011 Date Tag Installed Item Locked Out Item Location Lockout Inspector Date Tag Removed Removal Inspector
9. edures If a hazardous situation is encountered it should be brought immediately to the attention of the proper individual for hazard abatement The following sections identify various types of hand and power tools and their potential hazards They also identify ways to prevent participant injury through proper use of the tools and through the use of appropriate personal protective equipment PPE HAND TOOLS Hand tools are tools that are powered manually Hand tools include anything from axes to wrenches The greatest hazards posed by hand tools result from misuse and improper maintenance Some examples include the following If a chisel is used as a screwdriver the tip of the chisel may break and fly off hitting the user or other participants If a wooden handle on a tool such as a hammer or an axe is loose splintered or cracked the head of the tool may fly off and strike the user or other participants If the jaws of a wrench are sprung the wrench might slip If impact tools such as chisels wedges or drift pins have mushroomed heads the heads might shatter on impact sending sharp fragments flying toward the user or other participants The Safety Team is responsible for the safe condition of tools and equipment used by participants Unsafe hand tools shall not be issued for use Participants should be trained in the proper use and handling of tools and equipment Participants when using saw blades knives or other tools sh
10. gency procedures for all items coved by the MSDS system Participants The participants responsibilities include but are not limited to e Maintaining a safe work environment e Following safety instructions e Participating in all required safety training e Reminding others when unsafe practices are witnessed e Providing feedback to the Student Safety Captain on safety issues as they arise The entire team is responsible for ensuring the safety of all participants Everyone is expected to behave in a respectful manner at all times both at the home base and at competitions SAFETY PROCEDURES Specific safety procedures to be developed and disseminated to the participants through the Student Safety Captain or other appropriate experts are General Safety Practices Machine Shop Safety Practices and Proper Use of Hand Held Tools Proper Use of Electrical Devices Lockout Tagout Procedures Techniques for Lifting or Raising the Robot Safe Practices with Energy Storage Devices Proper Handling of Wet Cell Batteries Oe OV CoN These procedures are given in Appendix A of this manual TRAINING A student shall not be allowed to use items nor participate in procedures covered by the above listed safety procedures until it has been certified and recorded that the student has been fully trained by either the Student Safety Captain or one of the mentors for the respective procedures This applies to all participants Training records for
11. lech Fire FIRST ROBOTICS TEAM 225 YALU York Adams Lancaster United TEAM SAFETY MANUAL 2011 Competition Season Team Student Safety Co Captains Alec Bogart Safety Mentor Jim Bogart Team President Chuck Thomas GOAL The goal of this manual is to provide a foundation for FRC Team 225 to develop and maintain safe and enjoyable work environments both in its facilities and at competitions SCOPE The responsibilities of all team members are described safe work practices are reviewed training and testing requirements are outlined and record keeping requirements are defined RESPONSIBILITIES Safety Mentor The Safety Mentor s responsibilities include but are not limited to e Developing specific safety procedures e Training the Student Safety Captain to be able to coordinate training of all participants e Maintaining an up to date list of Material Safety Data Sheets MSDS e Training the Student Safety Captain on emergency procedures for all items covered by the MSDS sheets Student Safety Captain The Student Safety Captain s responsibilities include but are not limited to e Performing and tracking safety training of all participants e Providing support to participants on safety questions e Performing safety audits and maintain records of infractions and corrective actions e Knowing where the MSDS binder is stored and having access to it at all times while the robot area is occupied e Learning the emer
12. m the plug Double insulated tools are available that provide protection against electrical shock without third wire grounding On double insulated tools an internal layer of protective insulation completely isolates the external housing of the tool The following general practices should be followed when using electric tools Operate electric tools within their design limitations Use gloves and appropriate safety footwear when using electric tools Store electric tools in a dry place when not in use Do not use electric tools in damp or wet locations unless they are approved for that purpose Keep work areas well lighted when operating electric tools e Ensure that cords from electric tools do not present a tripping hazard PORTABLE ABRASIVE WHEEL TOOLS Portable abrasive grinding cutting polishing and wire buffing wheels create special safety problems because they may throw offflying fragments Abrasive wheel tools must be equipped with guards that 1 cover the spindle end nut and flange projections 2 maintain proper alignment with the wheel 3 do not exceed the strength of the fastenings Before an abrasive wheel is mounted it must be inspected closely for damage and should be sound or ring tested to ensure that it is free from cracks or defects To test wheels should be tapped gently with a light non metallic instrument If the wheels sound cracked or dead they must not be used because they could fly apart in operation A
13. or have a block placed such that the jack cannot be unintentionally lowered SAFETY PROCEDURE 6 Safe Practices with Energy Storage Devices Communication is essential for safe operation around energy storage devices Energy storage devices include e Springs bands e Air cylinders e Capacitors e Flywheels The following requirements must be followed in order to accomplish this e All devices must have a respective indicator examples light klaxon to indicate that the device is energized The signal should be appropriate for the purpose and should be chosen considering any team participants with disabilities e All devices should have either a guard or a lockout device to prevent unintentional deployment or energy release SAFETY PROCEDURE 7 Proper Handling of Wet Cell Batteries This Procedure is copied from the document FIRST Robotics Competition TEAM SAFETY MANUAL pages 7 9 CAUTION Batteries contain acid This substance H2SOs is a corrosive colorless liquid that will burn your eyes skin and clothing The team mentor and safety captain should post the Material Safety Data Sheet MSDS and train all team members about battery safety You can find Emergency handling and first aid on the MSDS proper protection for handling cracked or damaged batteries and information on disposal of the battery http www mkbattery com images MSDS _smallsealed_line pdf General Damaged Battery Information Warnings Any battery
14. ould direct the tools away from aisle areas and away from other participants working in close proximity Knives and scissors must be sharp dull tools can cause more hazards than sharp ones Cracked saw blades must be removed from service Wrenches must not be used when jaws are sprung to the point that slippage occurs Impact tools such as drift pins wedges and chisels must be kept free of mushroomed heads The wooden handles of tools must not be splintered Iron or steel hand tools may produce sparks that can be an ignition source around flammable substances Where this hazard exists spark resistant tools made of non ferrous materials should be used where flammable gases highly volatile liquids and other explosive substances are stored or used POWER TOOLS Appropriate personal protective equipment such as safety goggles and gloves must be worn to protect against hazards that may be encountered while using hand tools Workplace floors shall be kept as clean and dry as possible to prevent accidental slips with or around dangerous hand tools Power tools must be fitted with guards and safety switches they are extremely hazardous when used improperly The types of power tools are determined by their power source electric pneumatic liquid fuel hydraulic and powder actuated To prevent hazards associated with the use of power tools workers should observe the following general precautions Never carry a tool by the cord or hose Ne
15. rolyte leaving a safe residue that can be disposed of in a conventional manner such as rinsing with water Put on the gloves before handling the battery Place the battery in the leak proof container for removal Be sure to neutralize any acid on the gloves before removing and storing them Follow emergency handling instructions of the MSDS and notify mentor Seek medical attention Properly dispose of the battery which is now a hazardous material Ata FIRST event Immediately send the person in contact with acid to the First Aid Station EMTs Report incident to the Pit Administration Supervisor so he she can fill out an Incident Report Provide team number and available information Obtain sodium bicarbonate from the Pit Administration Supervisor and carefully sprinkle the sodium bicarbonate on the spill then clean it and dispose of the now neutralized cleanup materials in the trash Dispose of the battery properly Read below Battery Disposal The Interstate Batteries Company hitp www interstatebatteries com has volunteered to accept and properly dispose of any FIRST team s batteries and you can find a location near you from the above web site Most retailers of automotive batteries will accept and properly dispose of them at no cost snara ng and Handling When a battery is neither connected to the robot nor the battery charger use the battery protector safety plugs FIRST provides in the Kit of Parts Keep the battery
16. t be kept in a log as part of the Team 225 Safety Manual The tag must be securely fastened to the faulty device preferably with a nylon cable tie The only persons authorized to remove a Lockout tag are Student Safety Captains mentors and facility maintenance personnel Immediately upon removal the person who removed the tag must sign it and also provide the date the tag was removed The tag shall then be filed in the Team 225 Safety Manual and the log filled in to indicate the removal date SAFETY PROCEDURE 5 Techniques for Lifting or Raising the Robot Communication and proper lifting techniques are necessary for safe lifting of the robot The following requirements must be followed in order to accomplish this e A team of 3 persons is required two to lift the robot and one to maneuver and operate the jack cart e One person will be designated as the lifting team leader This person will direct the others on when to lift and when to lower the robot This applies to both unloading and loading the robot from to the jack cart and any other location as needed e The lifting points must be clearly marked on the robot Team participants must use these locations exclusively in order to prevent personal injury and damage to the robot and jack cart e When the robot is being worked on in the competition pit area it must be elevated on the jack cart to a reasonable height to prevent back strain The jack must be ina locked safety position
17. that is visibly damaged in any way is dangerous and unusable and should be set aside and handled accordingly because 1 It contains stored electrical energy that could cause the battery to rapidly heat up due to an internal electrical short circuit and possibly explode 2 The 12V batteries FIRST provided in your Kit contain sulfuric acid that will burn human tissue on contact Immediately flush any contacted skin with a large quantity of water Seek medical treatment Periodically inspect your batteries for any signs of damage or leaking electrolyte Remember that a dropped battery may be cracked but the crack may not be visible and might eventually leak electrolyte Don t take a chance Don t use it Treat it as a hazardous material and process it in accordance with the battery s MSDS Necessary Safety Materials FIRST recommends that teams keep the following items readily available wnenever working with batteries 1 2 A box of bicarbonate of soda to neutralize any exposed acid electrolyte A pair of acid resistant rubber or plastic leak proof gloves to wear when handling a leaking battery A suitable non metallic leak proof container in which to place the defective battery Procedure for Handling a Leaking Battery When an electrolyte leak occurs Neutralize it by pouring the bicarbonate of soda on all wetted surfaces The bicarbonate of soda itself is not dangerous and will react with the acid in the elect
18. the form from the regularly scheduled safety inspections Each violation should be accompanied by a corresponding Corrective Action report The Corrective Action report should be either written on the inspection form on which the violation was reported or written on a separate sheet and attached stapled to the respective inspection form APPENDIX A SAFETY PROCEDURES SAFETY PROCEDURE 1 General Safety Requirements Parts of this procedure are copied from the document FIRST Robotics Competition TEAM SAFETY Manual General Safety Guidelines e Non tinted ANSI approved safety glasses should be worn by all participants while in the robot build area and other areas where tools are used e Closed toe shoes should be worn at all times while in build work areas and at competitions e Work gloves should be worn whenever handling heavy or sharp items or when working with tools as appropriate e Always lift with your legs not your back to prevent back strain injury e Always walk and work in a thoughtful manner Basic Cleanliness and Organization e Electrical cords should not be laid across walkways nor in other areas where team members may be walking without being properly secured or covered This is a possible tripping hazard NOT ACCEPTABLE ACCEPTABLE Photos from Los Alamos National Laboratory EFCOG Electrical Improvement Project e tems that protrude into the workspace such as boards metal bars pipes etc shall be properl
19. ttp www askthebuilder com B174_Extension_Cord_Size_Chart shtml Step 1 Determine the amperage of the tool s being used Here is a handy list of some common electric power tools The average amperage is listed below the tool Always check on your tool label for its specific amperage Circular saw 12 to 15 amps Power drill 3 to 7 amps Table saw 15 to 20 amps Reciprocating hand held saw Sawzall 6 to 8 amps Step 2 Calculate the length of the cord you will need Of course you want to determine the maximum distance you think you will be from a permanent electrical outlet Step 3 Use the following list to select the proper gauge extension cord Remember wire gauge refers to the thickness of the actual copper wire As a wire gets thicker it can carry more electricity amps To confuse us someone long ago decided that as a wire gets thicker bigger the gauge number should get smaller 16 Gauge Cords Any 16 gauge cord between 0 and 100 feet long will adequately handle tool loads up to 10 amps 14 Gauge Cords Any 14 gauge cord between 0 and 50 feet long will adequately handle loads between 10 and 15 amps 12 Gauge Cords If your tool load is between 10 and 15 amps and the length of the cord is 50 to 100 feet you need a 12 gauge cord to safely power any tool SOLDERING Soldering can be dangerous because of the heat from the iron and the chemical fumes and vapors released from the solder and flux respectively
20. ver yank the cord or the hose to disconnect it from the receptacle Keep cords and hoses away from heat oil and sharp edges Disconnect tools when not using them before servicing and cleaning them and when changing accessories such as blades bits and cutters Keep all people not involved with the work at a safe distance from the work area Secure work with clamps or a vise freeing both hands to operate the tool Avoid accidental starting Do not hold fingers on the switch button while carrying a plugged in tool Maintain tools with care keep them sharp and clean for best performance Follow instructions in the user s manual for lubricating and changing accessories Be sure to keep good footing and maintain good balance when operating power tools Wear proper apparel for the task Loose clothing ties or jewelry can become caught in moving parts Remove all damaged portable electric tools from use and tag them Do Not Use GUARDS The exposed moving parts of power tools need to be safeguarded Belts gears shafts pulleys sprockets spindles drums flywheels chains or other reciprocating rotating or moving parts of equipment must be guarded Machine guards as appropriate must be provided to protect the operator and others from the following Point of operation In running nip points Rotating parts Flying chips and sparks Safety guards must never be removed when a tool is being used Portable circular saws ha
21. ving a blade greater than 2 inches 5 08 centimeters in diameter must be equipped at all times with guards An upper guard must cover the entire blade of the saw A retractable lower guard must cover the teeth of the saw except where it makes contact with the work material The lower guard must automatically return to the covering position when the tool is withdrawn from the work material OPERATING CONTROLS AND SWITCHES The following hand held power tools must be equipped with a constant pressure switch or control that shuts off the power when pressure is released drills tappers fastener drivers horizontal vertical and angle grinders with wheels more than 2 inches 5 08 centimeters in diameter disc sanders with discs greater than 2 inches 5 08 centimeters belt sanders reciprocating saws saber saws scroll saws and jigsaws with blade shanks greater than 1 4 inch 0 63 centimeters wide and other similar tools These tools also may be equipped with a lock on control if it allows the worker to also shut off the control in a single motion using the same finger or fingers The following hand held power tools must be equipped with either a positive on off control switch a constant pressure switch or a lock on control disc sanders with discs 2 inches 5 08 centimeters or less in diameter grinders with wheels 2 inches 5 08 centimeters or less in diameter platen sanders routers planers laminate trimmers nibblers sh
22. will be exposed The exception to fire resistant fluid involves all hydraulic fluids used for the insulated sections of derrick trucks aerial lifts and hydraulic tools that are used on or around energized lines This hydraulic fluid shall be of the insulating type The manufacturer s recommended safe operating pressure for hoses valves pipes filters and other fittings must not be exceeded All jacks including lever and ratchet jacks screw jacks and hydraulic jacks must have a stop indicator and the stop limit must not be exceeded Also the manufacturer s load limit must be permanently marked in a prominent place on the jack and the load limit must not be exceeded A jack should never be used to support a lifted load Once the load has been lifted it must immediately be blocked up Put a block under the base of the jack when the foundation is not firm and place a block between the jack cap and load if the cap might slip To set up a jack make certain of the following The base of the jack rests on a firm level surface The jack is correctly centered The jack head bears against a level surface and The lift force is applied evenly Proper maintenance of jacks is essential for safety All jacks must be lubricated regularly In addition each jack must be inspected according to the following schedule 1 for jacks used continuously or intermittently at one site inspected at least once every 6 months 2 for jacks sent out
23. y marked with brightly colored flags respectively to alert participants who must walk or work around these items This is a possible tripping and puncture hazard Example of Proper Flagging e Loose items such as tools fasteners and assorted parts should not be placed on the floor in the work area except for areas specifically designated for such This is a possible tripping hazard e When not in use cutting tools such as box cutters metal shears knives and saws should be either closed or sheathed This is a possible laceration hazard e The build and work areas shall be kept free of trash and debris and should be swept daily SAFETY PROCEDURE 2 Machine Shop Safety Practices and Proper Use of Hand Held Tools Sections of this Procedure are copied from OSHA 3080 and modified Participants should be trained in the proper use of all tools They should be able to recognize the hazards associated with the different types of tools and the safety precautions necessary Five basic safety rules can help prevent hazards associated with the use of hand and power tools Keep all tools in good condition with regular maintenance Use the right tool for the job Examine each tool for damage before use and do not use damaged tools Operate tools according to the manufacturers instructions Provide and use properly the right personal protective equipment Participants and mentors should work together to establish safe working proc
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