1000 TON TRANSFER PRESS SAFE WORK PROCEDURE ;DIE SETUP/CHANGEOVER

June 27, 2018 PRESS 23 DIE SETUP / CHANGEOVER LOCKOUT TAGOUT 1
SAFE WORK PROCEDURE
PRESS 23 WITH LINEAR TRANSFER
DIE REMOVAL/SETUP/CHANGEOVER LOTO
Created by : Julian Kalac Approved by AGM Department Press Shop
Date Created June 25 2018 Revision Date: N/A Press No. 23
PERSONAL PROTECTIVE EQUIPMENT
CSA or ANSI equivalent personal protective equipment must be worn
APPLICABLE LAWS IN ONTARIO
This procedur e is based on the requirements of the Ontario Electrical Safety Code, and
Regulation 851 Industrial Establishments of the Occupational Health and Safety Act.
Standards used in this procedure are based on CSA-Z460 and CSA Z142-10
ACTIVITIES PERMITTED WITH THIS PROCEDURE :
1. Inspecting dies
2. Maintenance of dies
3. Stock guide adjustments
4. Starting coil stock
5. Removing Scrap
6. Clearing Jams
7. Adjusting lube line in the die
8. Adjusting sensors in the die
For all other activities must follow the LOTO MASTER PLACARD and safe work procedures for
isolating energy on equipment being maintained
Lock Our Tag Out Criteria used for this procedure:
If any part of the body will enter the space between the upper and lower die sections, die blocks must
be inserted per the standard LOTO procedure for this press. Tools should be used to reach into die
areas to assist in starting coils, removing scrap and clearing jams.

SAFE WORK PROCEDURE
The different sources of hazardous energy and methods used to isolate them are shown below
Use Safety Blocks , Ram Or Die Blocks To
Block The Weight
Kinetic energy FLYWHEEL Rams, blades
Stop and block machine parts (e.g., stop
flywheels , disengage clutch , and ensure that
they do not recycle); review entire cycle of
mechanical motion, ensure that all motions are
stopped.
RAM WEIGHT, BOLSTER
Potential Energy,
Gravity
Hydraulic pressure
hydraulic systems (e.g., hydraulic
presses, rams, cylinders, hammers)
Shut off, lock (with chains, built-in lockout
devices, or lockout attachments) and tag
valves; bleed off and blank lines as
necessary.
Air pressure
pneumatic systems (e.g., lines,
pressure, accumulators, air surge
tanks, rams, cylinders)
Shut off, lock (with chains, built-in lockout
devices, or lockout attachments) and tag
valves; bleed off excess air; if pressure cannot
be relieved, block any possible movement of
machinery.
1- Turn off power at machine first (i.e., at point
of operation switch), and then 2- at the main
disconnect switch for the machine; 3- lock
and tag main disconnect switch . Disconnect
safety block plug and lock out plug
ENERGY FORM ENERGY SOURCE LOCKOUT METHODS
Electricity
power transmission lines; machine
power, motors; solenoids; capacitors,
interlock ram blocks

SAFE WORK PROCEDURE
LOCKOUT / TAGOUT PROCEDURE DIE SETUP AND DIE CHANGES
DIE CHANGE-OVER / DIE SETUP STEPS
1. Run out material.
2. Park transfer, TURN OFF POWER TO DRIVES AND LOGOUT HMI (LINEAR Lockout)
3. *SHUT DOWN PRESS USING MASTER STOP -WAIT UNTIL FLYWHEEL HAS COME TO A
FULL STOP
4. *RAISE THE RAM AND LOCK OUT THE PRESS USING SAFETY BLOCKS, and lock out the
plug with your lock (see next page ) ----1min per ram block
5. Unclamp & open die, clean die , inspect it for wear
6. REMOVE SAFETY BLOCKS AND LOCK FROM BOLSTER
7. Move Bolster up and out.
8. Recipe & Ram adjust.
9. Clean tracks on bolster part.
10. Bolster in and clamp.
11. *RAISE THE RAM AND LOCK OUT THE PRESS USING RAM BLOCKS (same as # 4)
12. Close die & clamp, connect sensor and lube cable.
13. REMOVE SAFETY BLOCKS AND LOCK FROM BOLSTER (same as # 6)
14. Hook up transfer bar
15. Login into HMI Linear, turn on drives and UN-Park transfer
16. Line fill through manual hits - set to continuous
NOTE: ITEMS WITH * ARE LOTO POINTS SPECIFIED ON LOTO PLACARD DIE SETUP

SAFE WORK PROCEDURE
BOLSTER ENTRY AND E-STOP LOCK OUT
Before entering the bolster from either the rear or front the opeprator must push the the E-stop button
and must lock out using hius/her lockout device.
LIGHT CURTAIN AREA
When the person remains in the light curtain area, the person is protected from accidental restarting of
the press and all hazardous energy are contained. However the area outside light curtain, specifically
the bolster is not detected by the light curtain and not safe without locking out. Therefore before the
person steps foot onto the bolter that person MUST lock out the ESTOP by placing a cover over
it, twisting the cover onto it
PROTECTED AREA BY LIGHT CURTAIN

SAFE WORK PROCEDURE
STOPPING THE MOTOR AND FLYWHEEL
Before stopping the press notify everyone affected , i.e. supervisor, lead hand, operators and
maintenance if needed . The flywheel generates kinetic energy that drives the press ram in the
downward stroke, To stop the press drive motor and flywheel press the MASTER STOP BUTTON
which will stop the motor and flywheel.
It is critically important to ensure that the flywheel has stopped before continuing
Wait for the flywheel light to come on before inserting the ram blocks.
Master stop button
Flywheel Stopped Light
Flywheel Stopped Light

SAFE WORK PROCEDURE
As per section CSA z142- “the press is not considered locked out until the flywheel has
stopped” If the flywheel has not stopped within 2 minutes apply the brakes and continue
applying the brakes until the flywheel has come to a full stop.

SAFE WORK PROCEDURE
LOCKING OUT THE MASTER STOP
Alternative lockout method
LOCKED PLUG ON THE
SAFETY BLOCK

SAFE WORK PROCEDURE
Section 7.4 CSA Z460 permits other types of lock out /control of hazardous energy other than
traditional lock out tag out. The Master Stop is the only control that shuts off the motor and stops the
flywheel. In some cases where the die is setup, clamped in position, but there are material feed issues,
multiple minor quick adjustments required or when changing grippers on the transfer is required ,
locking out using safety blocks may not be effective and may create more hazardous conditions for the
operators.
Specifically in situations where operator exposure time in the die< 30 seconds and 2 T-stands
are being used to cycle the press, locking out with safety blocks will increase the exposure under the
die from 30 seconds to 2 min and may not permit the resolution of the material ejection / feed issues. In
those cases alternative safer way is to lock out the master stop after the flywheel has stopped
make the quick adjustment remove the lock and restart the press, The 2 hand trip controls by both
operators is required in all circumstances
LOCKOUT PROCEDURE FOR DIE REMOVAL “ZERO KINETIC ENERGY STATE”.

SAFE WORK PROCEDURE
1. Identify Lockout Situations and Energy Sources
Assess equipment energy sources (figure 1.0), either potential or kinetic and determine
the most effective method to achieve a “ZERO ENERGY STATE”. Contact Safety Engineer to
help identify system shutdown procedures.
2. Notify Persons Affected
Once energy sources have been isolated, notify affected personnel of the shutdown.
3. Shutdown Procedure
Stop the press motor by pressing the master stop button, and selecting the OFF condition. Place a lock
cover over the master stop and lock it out. Disconnect the interlocked RAM block by removing the RAM
block connector.
4. Verify Flywheel Complete Stop –CRITICAL STEP
Verify that the flywheel has come to a full stop before placing the ram block into the press. The light at
the press control will turn on when the flywheel stopped. Also check the rear of the press and see if it
has stopped, Use a flywheel brake to stop the flywheel
WARNING : DO NOT PERFORM DIE CHANGES WHILE THE FLYWHEEL IS RUNNING,
5. Install Ram blocks
Raise the ram and Lock Out the press using ram safety blocks. Wait for the flywheel to stop, and install Ram
Blocks in place on the bolster.
6. Verify Effectiveness of Lockout—ZERO ENERGY
Try starting the press by pushing the start button, and 2 hand trip controls
Try starting the hydraulic pump and see if the bolster will move.
Press coil feed and try to cycle the feeder. If the feeder does not move, flywheel stopped light is on and the press
lights remain off and press will not start then you have achieved ZERO ENERGY STATE and can perform die
change
RESCUE AND RECOVERY

SAFE WORK PROCEDURE
IF A PERSON BECOMES TRAPPED IN THE PTC 1000 TON PRESS # 23:
Do not start motor.
Assess the problem and do the following :
Call maintenance and senior press shop personnel to Press
Crank will not move with light curtain blocked. Switch key switch for Ram/Slide
adjustment to 'ON' and reactivate power
Move Ram/Slide to free person:
If a person is trapped BELOW the Ram/Slide, use Ram/Slide adjust UP to raise the
Ram/Slide
If a person is trapped ABOVE the Ram/Slide, Use Ram/Slide adjust DOWN to lower the
Ram/Slide
If Ram/Slide adjust is not enough to free the person, maintenance must make changes to
further move the Ram/Slide Remove the trapped person and provide first aid
Call 911 if required
Safety Standards:
ANSI B11.0-2010 – Safety of Machinery – General Requirements and Risk Assessment

SAFE WORK PROCEDURE
ANSI B11.TR3-2000 – Risk Assessment and Risk Reduction – A Guide to Estimate, Evaluate
and Reduce Risks Associated with Machine Tools
ANSI/RIA R15.06-1999 (R2009) – For Industrial Robots and Robot Systems – Safety
Requirements
ANSI/PMMI B155.1-2011 – Standard for Packaging Machinery and Packaging-Related Converting
Machinery – Safety Requirements for Construction, Care, and Use
SEMI S10-0307 – Safety Guideline for Risk Assessment and Risk Evaluation Process
CSA Z432-04 – Safeguarding of Machinery – Occupational Health and Safety
CSA Z434-03 – Industrial Robots and Robot Systems – General Safety Requirements
CSA Z460-05 – Control of Hazardous Energy – Lockout and Other Methods
ISO 12100:2010 – Safety of machinery – General principles for design – Risk assessment and
risk reduction
X
Safety Manager
X
DEPARTMENT MANAGER
X
GENERAL MANAGER

SAFE WORK PROCEDURE

SAFE WORK PROCEDURE
SAFETY BLOCKS REQUIREMENT
The CSA standard Z142-10 requires that Safety Blocks be used whenever dies are being repaired in
a press or when work of any kind is being performed between the slide and bolster. Safety
Blocks are placed between the die punch and holder and must be rated to support the combined
static load of the slide and associated components.
Correct Usage Safety Blocks must be used when anyone is working in and around the die area of a
press. An electrical interlock must be attached to the Safety Block so that the press cannot be
operated when the blocks are in place. When not being used the blocks must be stored in a location
where the electrical interlock can be interfaced with the press controls ensuring the press can only be
started when the block is in the stored position, i.e. not in the press.

1000 TON TRANSFER PRESS SAFE WORK PROCEDURE ;DIE SETUP/CHANGEOVER

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