November 2008
Centrally control all aspects of lockout safety
Erlanger, Kentucky (November 7, 2008) – The Iso-Lok Doc Combo from Castell combines the features of a lockable document holder with those of a safety lockout station and group lockout box. Securely keeping both the permit to work documents and lockout equipment in the same unit, all aspects of lockout safety can now be controlled and monitored from one central location.
Up to five Permit to Work documents can be safety stored in the strong, clear Perspex cover sleeve, and ten more in a compartment behind the unit. The strong, lightweight aluminum box backboard is designed to securely hold keys, padlocks and multi-clasps (up to 15 total).
Once a Permit to Work has been completed, it can be displayed in the cover sleeve. After the necessary padlock(s) for the job have been removed, the sleeve is then locked closed by up to seven supervisor’s padlocks. Once the intended isolation is in place, the padlock keys are dropped into the slot on top of the box. They will be securely held there until the work is complete – the supervisor then opens the Doc Combo again, and the lock-out can be safely removed.
The Doc Combo also comes with a pad of 10 Permit to Work documents, and can be arranged for left- or right-handed operation. The aluminum box is finished in a durable powder coating, has a tray for the dropped-in keys, and uses removable hooks to hold the padlocks inside.
The Doc Combo, and related lockout/tagout accessories, can be quickly and securely ordered from the Iso-Lok section of www.castell.com, or by calling 859-341-3075.
December 2007
Drive-away prevention system eliminates unscheduled truck departures
Erlanger, Kentucky (December 20, 2007) – Unscheduled truck departures increase risk to workers and the potential for damage to loading docks and equipment. The Salvo loading dock safety system from international safety expert Castell ensures that a particular sequence of events happens before a truck is able to pull away from the dock. A new product design and complete kit purchase option have increased ease of installation and shortened order lead times.
The key to the Salvo system is the Salvo gladhand lock. Once the gladhand lock is attached to the truck’s brake line, ensuring that brakes are applied and trailer movement has stopped, a uniquely coded key is released. The key is then used in either the automatic or manual door lock, which traps the key, and allows workers inside the plant to unbolt the lock and begin loading or unloading the trailer. When work on the trailer is complete, the door interlock is bolted and the key needed to open the Salvo gladhand brake lock is released, making it possible for the driver to depart.
Castell is now packaging the safety system as a complete kit, with all system components and control panel wiring included. A one-size-fits-all design for the Salvo bollard, brackets and barrier chain set, and modular mounting rack model have lowered customer cost and made installation easier. Castell has also increased durability with a new temperature resistant gladhand lock design, and weatherproof stainless steel storage box. The entire kit is stocked and shipped from Erlanger, Kentucky with short lead times.
June 2007
Drive-away prevention system in place at Maryland distribution facility
Erlanger, Kentucky (June 18, 2007) – When a truck pulled away prematurely from his plant, causing a dock plate to fall, warehouse Distribution Superintendent Chris Gagliardi was convinced of the need to physically restrain trucks during loading and unloading. The incident could have caused serious injury to a worker at Millennium Inorganic Chemicals’ Baltimore, Maryland distribution facility. Millennium selected Castell’s Salvo trailer interlocking safety system to prevent unscheduled truck departures, reducing risk to workers and potential damage to loading docks and equipment.
In choosing a safety solution, Millennium evaluated both traditional bar systems and the Salvo system. Salvo’s error proof design and cost-effectiveness were driving factors in its selection. Eight Salvo Automatic Interlock Systems were installed at the plant. Each system consists of a Salvo gladhand lock, control panel, automatic door interlock and barrier chain.
Upon arriving at the plant’s loading docks, drivers attach the Salvo gladhand lock to their brake line, securing the device in place and releasing a uniquely coded key. The lock ensures that brakes are applied and trailer movement has stopped, in compliance with FMSCA’s braking requirement. The driver then turns that key in the exterior control panel, which traps the key, disengages the automatic door interlock and alerts workers inside the plant that it is safe to unbolt the lock, remove the barrier chain and begin loading or unloading. Until the barrier chain is replaced and the automatic door interlock is bolted, the control panel will not release the key needed to open the Salvo gladhand lock, making it impossible for a driver to depart.
“Since installing the systems over a year ago, we haven’t had a single incident of a truck pulling away. Our workers have fully embraced the Salvo’s error proof design and the peace of mind it gives them,” said Gagliardi.
“The Salvo system avoids the pitfalls of procedures that rely on drivers to avoid accidents,” Gagliardi continued. “One of these methods is requiring drivers’ keys while loading and unloading; we still have a set of keys from months ago. Clearly the driver did not give us the keys to his trailer. Without the Salvo system, he could have easily made an unscheduled and unsafe departure.”
May 2007
Durable trapped key interlocks ensure precipitators are powered down prior to access.
Erlanger, Kentucky (May 4, 2007) – Maintenance on electrostatic precipitators can be dangerous if equipment is not first powered down. Castell’s range of heavy-duty interlocks guarantees the safety of workers operating electrostatic precipitators by preventing access to live equipment.
The electrodes and collection plates in precipitators require maintenance to perform at optimum levels. With electrodes carrying a charge of over 10,000 volts, stringent safety procedures are vital if operator access prior to isolation of the LV/HV transformer is to be prevented.
Castell’s trapped key interlocks force workers to adhere to a step-by-step process every time internal access to a precipitator is needed. Each step releases a key which in turn permits activation of the next stage in the process. This system ensures that access to live precipitators is impossible.
Typical light duty locking devices, such as pin tumblers, are prone to plugging and performing poorly in the high fly-ash environment within precipitators. Castell’s durable lock mechanism avoids this problem with a sealing key and cap to keep out dirt or dust. This design, coupled with Castell’s robust, large handled key, guards against failures. The key is capable of transmitting much more torque to the lock than a standard pin tumbler key for ease of operation.
March 2007
Motion monitoring unit permits safe access without unnecessary downtime.
Erlanger, Kentucky (March 9, 2007) – Safe access to equipment with variable rundown times can be difficult to judge. The BEMF motion-monitoring device from Castell Interlocks guarantees that motor-driven equipment such as mixers, hammer mills and pellet mills has completely stopped before access is granted. Safety is increased while downtime is reduced, compared to fixed time delay systems.
While an electric motor is rotating, whether powered or not, an electromotive force is generated. This force is measured by sensors in the BEMF unit. A key, corresponding to a lock on the machine’s guard hatch, will not be released until the sensors register zero speed. The key is then released and can be used to gain access to the machine. Access is granted as soon as safely possible, unlike fixed time delay systems which can overcompensate run-down times for lighter loads.
The BEMF prevents access to the equipment while it is running. Entrance to the equipment is immediate after reaching zero speed. The equipment cannot be restarted until personnel has safely withdrawn, then closed and locked the guard hatch.
The BEMF unit can be connected to both A.C. and D.C. motors, including soft start motors. It is designed to provide the highest level of safety at all times; like other Castell key interlock systems, it is an approved alternative method to Lockout-Tagout requirements under the ANSI Z244 Standard.
