Bootcamp ONLINE! Heat and Pressure Hazards, Confined Spaces and - PowerPoint PPT Presentation

- Part 3- Brewery Safety Bootcamp – ONLINE! Heat and Pressure Hazards, Confined Spaces and Lockout/Tagout, and Operating During Covid-19 May 15, 2020

Matt Stinchfield Safety Ambassador Brewers Association Boulder, Colorado @MattStinchfield #SafetyAmBadAssador mstinchfield

UNIQUE BREWERY HAZARDS HEAT AND PRESSURE

KETTLE BOILOVERS

KETTLE BOILOVERS TASKS OUTCOMES CAUSES • Wort Boiling • Deep Tissue • Overcharging Burns/Fatality kettle volume • Hop Addition • Permanent • Lack of foam Disability controls • PTSD • Rapid hop addition • Production • Failure to Shutdown and Product Loss monitor temp.

Boiling Wort ca. 213 ºF - Instantaneous - Caustic Cleaning 170 ºF - ca. 200 ms - Mash @ Conversion 152 ºF - ca. 1.5 sec -

Systemic Systemic Ef Effects Bey ects Beyond the Bur ond the Burn Site n Site Body Responds to Burn by • Releasing cytokines and other anti-inflammatory mediators Results • Bronchoconstriction • Increased basal metabolic rate • Cardiovascular issues • Heart contractions decreased • Vasoconstriction of organs • Reduced immune response Source: National Center for Biotechnology Information, US National Library of Medicine.

ENGINEERING PROCEDURAL CONTROLS • Stick to design volumes: 30-50% • Foam shutoff switch freeboard • Anti-foam agent • Avoid “line of fire” • Spray hose to cool • Gradual hop KETTLE • Temperature sensor addition, only after BOILOVERS hot break • Manway positioning in regard to operator • Follow an SOP • Eye protection, insulated gloves, long pants over boots

Thanks to our generous sponsor

Andy Clearwaters Health and Safety Manager Bell’s Brewery Comstock, Michigan andy-clearwaters-3069989a

PRESSURIZED SYSTEMS

PRESSURE HAZARD ASSESSMENT TASKS OUTCOMES CONTROLS • • • Moving Beer Equipment Failure Use gauges • Tank Vacuum • • Keg Cleaning Primary & Secondary Implosion Regulators • Vessel CIP • Tank Pressure • Cylinder Restraint • Using Compressed Air Explosion • and Gases: CO 2 , N 2 , O 2 Pressure / Vacuum Relief • Flying Objects Valves • Oxygenating • Chemical Spray • • Carbonating Burst Disks • Asphyxiation • Packaging • Proper Fittings • Wort Burns • Wort Production

ENGINEERING PROCEDURAL CONTROLS & SWP • Safety valve • Follow an SOP • Pressure Relief • Understand PRESSURIZED Valve (PRV) chemical and SYSTEMS physical reasons for • Vacuum Relief Valve tank failure (VRV) CELLAR VESSEL • Inventory valves • Burst disk, or HAZARD CONTROLS • Schedule relief Rupture disk valve inspection and • Correct sizing and cleaning pressure/vacuum settings

PRESSURE RELIEF DEVICES FOR VESSELS Storage Tank Relief Device (protects overpressure and vacuum) Rupture Disk Conventional Common Spring- Pressure Relief loaded Tri-clamp Valve Pressure Relief Valve Pressure Relief Valve Lever Action / Rupture Disk Pressure Relief Valve Combination

ENGINEERING PROCEDURAL CONTROLS & SWP • Secondary regulators • Follow an SOP and pressure gauges • Understand how to PRESSURIZED at point of equipment SYSTEMS depressurize connection system before • Safety valves uncoupling PACKAGING AND DISPENSE HAZARD • Plexiglas panels • Know correct CONTROLS operating pressure • Proper connections of all equipment • Oetiker clamps • Regularly inspect, • Factory installed cleaning, replace hose fittings • wearable parts DO NOT USE worm clamps

WAY TO GO!!! PRESSURE HAZARDS NO NO NO!!! DON’T BE A HOSER!

Thanks to our Thanks to our generous generous sponsor sponsor

Chris Bogdanoff Head Brewer & BA Safety Subcommittee Chair Heroes Restaurant and Brewery Anaheim, California

DRY HOPPING FAILS

DRY HOPPING FAILS, a.k.a. “POPCORNING” or “HOP VOLCANO” TASKS HAZARDS CONTROLS • Engineering • Dry Hopping • Flying Objects Controls due to • Adding • Established Pressure Seasonings or Procedures • CO 2 Fruit Flavoring • Safe Work Overexposure • PRV Cleaning Practices • Risk of Falling • Working at from Height height • PPE • Fall protection

PRESSURE WORKING AT HAZARDS HEIGHTS • Blow down CO 2 head • Choose best system pressure per an SOP your resources allow • Scissor lift • Keep pressure gauges DRY HOPPING • Rolling platform and PRVs clean, stairs operational • Extension ladder or HAZARD • Don’t exceed design step ladder CONTROLS volume • Harness, Anchor, • Add ingredients slowly Tether • Catwalk • Consider hop doser or recirculation equip.

Andrew Dagnan Environmental and Safety Manager Wicked Weed Brewing Co. Asheville, North Carolina

CONFINED SPACES & LOCKOUT/TAGOUT INCREASE YOUR AWARENESS & SYSTEMATIZE YOUR PROCEDURES

ACCIDENTS CONFINED • Confined space SPACES accidents are rare • Often fatal • Often involve more than one person • Accidents are easily preventable • Majority of deaths are would-be rescuers

DEFINITION EXAMPLES • Brewhouse Vessels CONFINED SPACE MT, LT, BK, WP, HLT, • Large enough to CLT bodily enter and • Fermenters perform work • Limited means of • Bright Tanks entry or exit • CIP Tanks • Not designed for • Yeast Brink continuous human • Wastewater treatment occupancy tanks, sumps • Grain Silos

CONFINED SPACE HAZARD ASSESSMENT TASKS HAZARDS CONTROLS • Brewhouse • Bad Atmosphere, • Air Monitoring Vessel Cleaning e.g. O 2 Deficiency • Engineering • FV/BBT Cleaning • Mechanical Hazards • LO/TO • Water and Waste- • High Temperature • Forced Air Flow water Inspection • Engulfment • Administrative • Grain Silo • Hazard • Falls Inspection Assessment • Reclassification • SOPs & Training

PERMIT-REQUIRED CONFINED SPACE QUALIFIERS Potential to contain Converging walls or Any other serious Engulfment hazard hazardous atmosphere floor hazard • • • • O 2 def. atmos. Grain Fermenters Mash mixer • • • • Elevated CO 2 Water Silos Lauter tun rake

HOW DO YOU PROPERLY ENTER A PERMIT-REQUIRED CONFINED SPACE? ENTERING MEANS If any part of the entrant’s body breaks the plane of an opening into a confined space … YOU MUST HAVE • Written Program • Hazard Assessment of Spaces • Entry Permits • Atmospheric Testing • Specific Safe Procedures • Authorized Entrant, Attendant • Emergency Rescue Procedures • Training

IS THERE AN ALTERNATIVE TO PRCS ENTRY REQUIREMENTS? RECLASSIFICATION • Space poses no actual or potential atmospheric hazard • All hazards within the space can be eliminated without entry into the space (LO/TO) • Useful for Brewhouse Vessels – MT, LT, BK, WP • Documentation • Written Program • Hazard Assessment • Written Procedure, including LO/TO • Training

LOCKOUT / TAGOUT CONTROL OF HAZARDOUS • To isolate and control ENERGY (LO/TO) hazardous energy sources • Electrical • Mechanical • Pneumatic, etc. • LO/TO equipment is specialized • Use LO/TO devices only for LO/TO work

WHEN TO USE LO/TO CONTROL OF • Remove or bypass HAZARDOUS any safety device ENERGY (LO/TO) on a piece of machinery • Place any part of your body into a point of operation where a danger zone exists during an operating cycle

LO/TO HAZARD ASSESSMENT - ACHIEVE A ZERO ENERGY STATE TASKS HAZARDS CONTROLS • Brewhouse • Mechanical Hazards • Engineering Vessel Cleaning • Crush/Pinch • LO/TO Devices • Packaging • Flying Objects • Administrative • Conveyors • Electrical • Energy Control • Fillers Procedures • Electric shock • Drop Packers • SOPs & Training • Electrocution • Palletizers • Fluid Energy Release • Single Sources • Bodily Injury • Electric Cords

TYPES OF HAZARDOUS ENERGY CONTROL OF • Electrical • Hydraulics (fluid) or HAZARDOUS pneumatic (air) ENERGY (LO/TO) • Mechanical • Chemical • Stored or potential • Radiation (nuclear (springs, gravity, etc.) gauges) • Thermal

ENERGY CONTROL PROCEDURE (ECP) • Procedural steps “TRY” STEP ECP is an SOP that describes shutdown • placement, • Verifies isolation and startup for removal, and • May release residual systems with multiple transfer of or stored energy energy sources LO/TO devices • Confirms correct • who has energy sources are responsibility for • Procedural steps controlled them • shutting down • Keep persons safe • Requirement for • isolating, while performing the testing a piece of blocking, and Try Step equipment to verify securing effectiveness of • restoring LO/TO devices – a.k.a. The TRY STEP

ENERGY CONTROL PROCEDURE (ECP) EQUIPMENT-SPECIFIC • Often includes images • Color-coded energy control points ONLINE ECP GENERATORS • Subscription-based • Some free tools available

LO/TO DEVICES LOCKS • Only used for LO/TO • Only 1 key • Key kept by operator being protected by LO/TO TAGS • Provide a message HASPS • Allow multiple locks

LO/TO DEVICES LOCK BOXES • Isolate small equipment from use • Allow multiple keys to be locked