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Definitions and Descriptions
Rockford Systems Glossary: Essential Safety Definitions & Descriptions
From the Code of Federal Regulations (CFR) § 1910.211
- Adjustable barrier guard means a barrier requiring adjustment for each job or die setup.
- Antirepeat means the part of the clutch/brake control system designed to limit the press to a single stroke if the tripping means is held operated. Antirepeat requires the release of all tripping mechanisms before another stroke can be initiated. Antirepeat is also called single-stroke reset or reset circuit.
- Bolster plate means the plate attached to the top of the bed of the press having drilled holes or T-slots for attaching the lower die or die shoe.
- Brake means the mechanism used on a mechanical power press to stop and/or hold the crankshaft, either directly or through a gear train, when the clutch is disengaged.
- Brake monitor means a sensor designed, constructed, and arranged to monitor the effectiveness of the press braking system.
- Clutch means the coupling mechanism used on a mechanical power press to couple the flywheel to the crankshaft, either directly or through a gear train.
- Concurrent means acting in conjunction and is used to describe a situation wherein two or more controls exist in an operating condition at the same time.
- Continuous means uninterrupted multiple strokes of the slide without intervening stops (or other clutch control action) at the end of individual strokes.
- Device means a press control or attachment that:
- (i) Restrains the operator from inadvertently reaching into the point of operation, or
- (ii) Prevents normal press operation if the operator’s hands are inadvertently within the point of operation, or
- (iii) Automatically withdraws the operator’s hands if the operator’s hands are inadvertently within the point of operation as the dies close, or
- (iv) Prevents the initiation of a stroke, or stops a stroke in progress when there is an intrusion through the sensing field by any part of the operator’s body or by any other object.
- Die means the tooling used in a press for cutting or forming material. An upper and a lower die make a complete set.
- Feeding means the process of placing or removing material within or from the point of operation.
- Fixed barrier guard means a die space barrier attached to the press frame.
- Foot control means the foot-operated control mechanism designed to be used with a clutch or clutch/brake control system.
- Foot pedal means the foot-operated lever designed to operate the mechanical linkage that trips a full revolution clutch.
- Full revolution clutch means a type of clutch that, when tripped, cannot be disengaged until the crankshaft has completed a full revolution and the press slide a full stroke.
- Gate or movable barrier device means a movable barrier arranged to enclose the point of operation before the press stroke can be started.
- Guard means a barrier that prevents entry of the operator’s hands or fingers into the point of operation.
- Hand feeding tool means any hand-held tool designed for placing or removing material or parts to be processed within or from the point of operation.
- Holdout or restraint device means a mechanism, including attachments for the operator’s hands, that when anchored and adjusted prevents the operator’s hands from entering the point of operation.
- Inch means an intermittent motion imparted to the slide (on machines using part revolution clutches) by momentary operation of the Inch operating means. Operation of the Inch operating means engages the driving clutch so that a small portion of one stroke or indefinite stroking can occur, depending upon the length of time the Inch operating means is held operated. Inch is a function used by the die setter for the setup of dies and tooling but is not intended for use during production operations by the operator.
- Interlocked press barrier guard means a barrier attached to the press frame and interlocked so that the press stroke cannot be started normally unless the guard itself, or its hinged or movable sections, enclose the point of operation.
- Jog means an intermittent motion imparted to the slide by momentary operation of the drive motor after the clutch is engaged with the flywheel at rest.
- Manual feeding means feeding wherein the material or part being processed is handled by the operator on each stroke of the press.
- Operator’s station means the complete complement of controls used by or available to an operator on a given operation for stroking the press.
- Part revolution clutch means a type of clutch that can be disengaged at any point before the crankshaft has completed a full revolution and the press slide a full stroke.
- Pinch point means any point other than the point of operation at which it is possible for a part of the body to be caught between the moving parts of a press or auxiliary equipment, or between moving and stationary parts of a press or auxiliary equipment or between the material and moving part or parts of the press or auxiliary equipment.
- Point of operation (from § 1910.217 Mechanical Power Presses) means the area of the press where material is actually positioned and work is being performed during any process such as shearing, punching, forming, or assembling.
- Point of operation (from § 1910.219 Mechanical Power-Transmission Apparatus) means that point at which cutting, shaping, or forming is accomplished upon the stock and shall include such other points as may offer a hazard to the operator in inserting or manipulating the stock in the operation of the machine.
- Presence sensing device means a device designed, constructed and arranged to create a sensing field or area that signals the clutch/brake control to deactivate the clutch and activate the brake of the press when any part of the operator’s body or a hand tool is within such field or area.
- Press means a mechanically powered machine that shears, punches, forms or assembles metal or other material by means of cutting, shaping, or combination dies attached to slides. A press consists of a stationary bed or anvil, and a slide (or slides) having a controlled reciprocating motion toward and away from the bed surface, the slide being guided in a definite path by the frame of the press.
- Pull-out device means a mechanism attached to the operator’s hands and connected to the upper die or slide of the press, that is designed, when properly adjusted, to withdraw the operator’s hands as the dies close, if the operator’s hands are inadvertently within the point of operation.
- Repeat means an unintended or unexpected successive stroke of the press resulting from a malfunction.
- Safety block means a prop that, when inserted between the upper and lower dies or between the bolster plate and the face of the slide, prevents the slide from falling of its own deadweight.
- Safety system means the integrated total system, including the pertinent elements of the press, the controls, the safeguarding and any required supplemental safeguarding, and their interfaces with the operator, and the environment, designed, constructed and arranged to operate together as a unit, such that a single failure or single operating error will not cause injury to personnel due to point of operation hazards.
- Single stroke means one complete stroke of the slide, usually initiated from a full open (or up) position, followed by closing (or down), and then a return to the full open position.
- Slide means the main reciprocating press member. A slide is also called a ram, plunger, or platen.
- Stop control means an operator control designed to immediately deactivate the clutch control and activate the brake to stop slide motion.
- Trip or (tripping) means activation of the clutch to “run” the press.
- Turnover bar means a bar used in die setting to manually turn the crankshaft of the press.
- Two-hand trip means a clutch actuating means requiring the concurrent use of both hands of the operator to trip the press.
- Two hand control device means a two hand trip that further requires concurrent pressure from both hands of the operator during a substantial part of the die-closing portion of the stroke of the press.
General Definitions
- Combustion Fundamentals — Introduces attendees to the basics of combustion. Topics include: the fire triangle, fuels type and properties, air/fuel ratios, lower explosive limits (LEL), basic burner designs — including nozzle and premixed, exhaust (draft).
- Gas Train and Controls Basics — Explains the function of the gas train, how various components/function each operate, typical arraignments, and good practices to follow for safe operation.
- Valve Testing: SSOV and Manual — The types of valves (manual ball, plug, auto safety shutoff valves) and their possible failure modes. Concepts covered include: bubble testing, lubricating plug valves, and resolution options.
- Interlock Testing — Brief review of ways to test common interlocks and permissive. Devices included: pressure switches, purge timers, position switches (including proof of closure), flame detectors, and temperature interlocks.
- Gas Piping and Repairs (NFPA 54) — The process for the safe removal and re-introduction of fuel gas piping when installing or repairing existing piping is reviewed. Lessons learned from two recent high-profile events are discussed as well as the changes that occurred in the National Fuel Gas Code (NFPA 54) as a result of them. The module concludes with tips for a safe start-up after repair/installation work.
- Combustion Control and Tuning (Basics) — Describes the features of four common types of firing rate control systems. Explains Fuel/Air ratios and goes over burner tuning and configuring premix systems. Customized to equipment and addresses key concepts, furnace pressures, burner set-up, control methods, system adjustments, nuisance trips and temperature overshoot issues.
- Relay and PLC Basics — How to read, understand, and apply three common control diagrams: ladder logic, PLC logic, and P&ID diagrams.
- Hazard Recognition — Instructs attendees how to use their senses (look, listen and feel) to observe and recognize possible safety hazards related to combustion. A suggested prestart checklist is stepped through while looking at photos of possibly dangerous scenarios. Function, composition, installation, and operational troubleshooting using a multimeter. Common temperature controller types as well as a brief review of PID loop parameters and troubleshooting.
- Burner Management Systems — Sequencing overview, fault conditions, BMS functions, and maintenance procedures.
- Troubleshooting Combustion Systems — Review of BMS faults, common issues, systematic approach to troubleshooting.
- Emissions and Analyzers — NOx, CO measurements, limits, controlling and tuning issues, proper tools and equipment use.
- Fuel Oil Systems — Various fuel types used in combustion process, BTU factors, dangers and code related repairs.
- Oxygen Burners and Systems — Review of oxygen burner types, fuel train considerations, and common applications.
- Radiant Tube Systems — Detailed review of radiant tube systems including: tube types, burner types, common applications, and maintenance tricks.
- Burners: Air Heating — Reviews typical burners used for air heating applications including: types, applications, selection, and maintenance.
- Burners: High Temperature — Reviews typical burners used for high temperature (furnace) applications including: types, applications, selection, and maintenance.
- Furnace Efficiency Basics — Illustrates how energy is lost from process combustion systems and demonstrates money-saving tips and processes when running furnaces. Introduces terms such as “preheated air,” “air infiltration,” and “pulse firing.”
- Heat Recovery Process — Review of heat recovery technologies including: recuperature, regenerative, and plate and frame applications.
General LOTO Terms
- Lockout – The process of placing a lock on an energy-isolating device to prevent the release of hazardous energy.
- Tagout – The placement of a warning tag on an energy-isolating device to indicate that it should not be operated.
- Energy-Isolating Device (EID) – A mechanical device that physically prevents the transmission or release of hazardous energy (e.g., circuit breaker, disconnect switch, valve, block).
- Hazardous Energy – Any form of energy (electrical, mechanical, hydraulic, pneumatic, chemical, thermal, etc.) that could cause injury or damage if released unexpectedly.
- Zero Energy State – A condition where all sources of hazardous energy are removed, relieved, or controlled to prevent unexpected startup or movement.
LOTO Program & Procedures:
- Energy Control Program (ECP) – A written program that outlines the employer’s policies, procedures, and responsibilities for implementing LOTO.
- Energy Control Procedure (ECP or LOTO Procedure) – Step-by-step instructions for shutting down and isolating equipment safely before performing maintenance or servicing.
- Verification of Isolation – The act of confirming that hazardous energy has been effectively controlled before work begins.
- Authorized Employee – A person who has been trained and is responsible for applying and removing lockout/tagout devices on machines or equipment.
- Affected Employee – An employee whose job is impacted by the LOTO procedure but does not perform lockout/tagout (e.g., machine operators).
- Other Employees – Workers who may be in the area where LOTO is being performed and must be aware of safety procedures.
LOTO Devices & Equipment
- Lockout Device – A device (such as a padlock or hasp) that physically prevents the operation of an energy-isolating device.
- Tagout Device – A warning tag that is attached to an energy-isolating device to indicate that it should not be operated.
- Group Lockout – A lockout method where multiple workers use a group lockout box or multiple locks to ensure energy control.
- Lockout Hasp – A device that allows multiple locks to be attached to a single energy-isolating device for group lockout.
Special LOTO Situations:
- Tryout – The process of attempting to start equipment after lockout has been applied to confirm energy isolation.
- Temporary Removal of Lockout/Tagout – A procedure that allows for temporary removal of locks or tags for testing or repositioning, followed by reapplication.
- Alternative Protective Measures (APMs) – Additional safeguarding methods used when traditional LOTO is not feasible, such as interlocks or control circuit devices.
- Stored Energy – Residual energy that remains in a system after shutdown, such as pressure in hydraulic lines or tension in springs.
- Capacitor Discharge – The process of safely releasing stored electrical energy from capacitors before maintenance.
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