Grain Engulfment Prevention
As summer nears its end, elevators are preparing for an influx of grain: cleaning bins, inspecting machinery and investing in new equipment to handle what will no doubt be another record harvest. During this time new employees will be brought onboard, and seasoned veterans will be bracing themselves, knowing what to expect from peak season. In the midst of making these necessary preparations, management should also be reviewing its safety and training policies.
When was the last time your team reviewed bin safety procedures and protocol? Has your facility ever hosted grain engulfment rescue training with employees and local first responders? For new employees and old, annual grain entrapment education and training is essential in preventing the unthinkable.
According to Purdue University’s Agricultural Safety & Health Program’s National Grain Entrapment Database, a log tracking entrapment cases since 1964, 38 grain entrapments occurred in 2009. This is up roughly 10% from 2007 and 2008; and it is the highest recorded number since 1993.
Entrapment incidents have been trending upward, but what’s driving this upswing?
Many point to the sheer volume of grain — corn in particular — being produced and handled in the United States. While other commodities can also pose a threat to careless individuals, most entrapment incidents occur in corn bins.
“Aside from the amount of corn being handled, the condition of the 2009 harvest has contributed to the recent spike in the number of fatalities,” says Wayne Bauer, safety and security director, Star of the West Milling Co., and former president of GEAPS.
A common thread links most engulfment incidents: poor grain quality. Bridging and other problematic formations create situations where employees feel compelled to enter the bin to dislodge grain. Simply keeping the grain in condition is one solution in combating grain entrapment incidents.
“If we’ve done our job putting grain into storage — and maintain it once it’s in the bin — there would be no reason to enter it,” Carol Jones, assistant professor, stored product engineering, Oklahoma State University, says.
The year-round demand for ethanol requires facilities to store grain for longer periods adding to the quality issue. Jones suggests elevators detect, monitor and address even minor grain quality issues before they reach a point when it is necessary to enter a bin to remediate the problem.
Grain quality aside, the installation of safer and more efficient systems will deter bin entrance. As new equipment is installed or existing structures are retrofitted with new equipment, Bauer suggests, for example, elevators add larger discharge sump holes (24’ x 24’) and decent service tunnels under the floor of the bin (7 feet high with good lighting and drainage) so employees can work safely and comfortably.
The general state of the economy may have also contributed to the tragic trend. As businesses run leaner than ever, the lack of excess labor may put employees in a position to attempt to clean a bin alone rather than with proper oversight, Bauer notes.
Perhaps an intangible, psychological factor plays a part in this equation: The refusal to acknowledge that grain can be dangerous, and treat it accordingly.
“It’s a human nature to believe we are safe at work; we hate to admit there is a hazard in what we’re doing,” states Mark Baker, coordinator for State Line Rescue. “And no one wants to admit it could happen to them.”
The only surefire way to combat and prevent the engulfment incidents is through proper safety training.
5 ENGULFMENT PREVENTION TIPS
Despite the level of experience an employee may have, new and seasoned employees alike are at risk for getting themselves into trouble — a combination of arrogance fueled by perceived experience (“I’ve done this a million times and nothing happened”) or naivety due to lack of proper training.
“You can’t assume every new employee comes to [you] with any training — there’s just too much at stake — so every employee needs to have some sort of conditioning and safety training within the first few days of their employment,” Jones explains.
While accidents do happen, it is the responsibility of the elevator to provide every opportunity to prevent it from happening. As elevators seek out training programs for their employees, there are five fundamental principles of engulfment prevention that can be stressed immediately:
1. Keep people out of the bins
Grain belongs in bins; people do not. “People get pretty cavalier about getting in and out of bins — especially if they’ve been doing it their entire career,” Bauer says. He suggests adopting a zero-entry mentality.
Don’t enter the bin unless absolutely necessary. Bauer and Jones suggest elevators take a serious look at their grain conditioning and reclaim systems to combat this necessity.
“Grain quality preservation and better equipment are the answer,” Jones says. “The answer is not to climb into the bottom of the bin and start poking around — which unfortunately seems to be the standard method right now.”
2. Never enter a bin alone
Should an individual need to enter a bin, never under any circumstance should that person work alone.
“Whether it’s a commercial operation or a farm, it is imperative for an individual to work with an observer or an attendant,” Baker says.
3. Adequate hands-on training
The best way to become familiar with safety and rescue equipment is by working with the equipment firsthand.
“Most facilities need to take training more seriously,” Bauer says. “Many do not provide appropriate hands-on training for the bin entrants and the observers.”
He suggests training sessions consist of both classroom and in-the-field instruction.
To ensure an understanding of the safety equipment during the hands-on portion of training, he suggests employees be required to demonstrate how to use the equipment.
“Until the employee can demonstrate they are comfortable with handling equipment and using techniques — and know what’s expected of them should a situation develop — you haven’t really done training yet,” Bauer says.
4. Follow entry permit
procedures
Take the appropriate amount of time to thoroughly complete OSHA’s entry permits, providing a firm assessment of the potential hazards. Who is your emergency response group? Make sure you have listed a capable emergency response group to assist you. Do not list an off-site group who has never been to your facility.
“There should have been some hands-on training before they are listed on the entry permit,” Bauer says. “You have to take the time to show [the local fire department] the spaces you’re dealing with so they can become familiar with your equipment and the facility.”
Also, whoever is listed on the permit needs to be an agency that can respond in a timely manner, and is trained and equipped properly to perform in that kind of an emergency.
“You can’t just call 911,” Bauer says. “In rural America, 85% to 90% of communities rely on local volunteer fire departments. You are responsible for conducting training with them so they understand how to deal with an incident.”
