Forensic Engineers and Consultants

Archive: Machinery and Equipment

The Use of Taglines to Control Crane Loads

The adequacy of a crane’s load line to support the weight of the object being lifted is an obvious concern when evaluating a crane lifting operation. Less obvious, but often equally important, is the presence and adequacy of taglines to provide control of the load orientation.

Taglines are simply ropes or lines that are Read More

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Industrial Equipment Failures and Construction Disputes

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At Warren, we frequently investigate losses involving industrial machinery.  Many of the losses involve workplace injuries, fires, or explosions; however, we also analyze industrial machinery and processes for other types of problems.  For example, we analyze failures of machinery or industrial processes to perform as expected or disputes that arise from the commercial supply and construction of such systems.  This can encompass a range of issues from failure to achieve required levels of product quality or production quantity, to matters concerning unclear specifications or contracts, Read More

WARREN WEBINAR: Property Claims Issues at Manufacturing Facilities

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LIVE WEBINAR: “Property Claims Issues at Manufacturing Facilities” | Presented by WARREN’s President and Senior Consulting Engineer, Jennifer Morningstar, P.E., CFEI.

COURSE LEARNING OBJECTIVES
The learning objectives of this course are to provide the attendees with information on the four major facets of property claims that are commonplace in manufacturing facilities.

They are:

  1. Subrogation against third parties;
  2. Boiler & machinery vs property claims;
  3. Scope of loss, and
  4. Business interruption

Each facet will be explored and exemplified by at least one case study.

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Heat Exchanger Failures Will Shut Your Process Down

Heat exchangers, as the name implies, are used to bring a process stream to a desired temperature.  They can heat or cool either gases or liquids. They are fairly intricate in their construction, therefore not the cheapest piece of equipment to purchase.  For that reason, facilities don’t keep “spare” exchangers lying around, so when they fail catastrophically, the entire manufacturing process goes down with them… and stays down until they are fixed or replaced. Ow!

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The CE Mark and What Should It Mean to You? Part Two

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In the previous blog (Part One) we discussed the backstory behind the two stylized letters CE and what it means to the design of machinery bearing the mark.   We outlined some of the requirements of the “Machinery Directive” (MD) which include what are known as “Essential Health and Safety Requirements.” The Essential Health and Safety Requirements incorporate an iterative risk reduction process during design that takes into account Read More

Machine Guarding and Risk Assessment

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The Occupational Health and Safety Administration (OSHA) “Top 10 for 2018” violations once again have Machine Safeguarding earning a position on the list. Machine safeguarding was the 9th most cited standard as noted in the list below:

  1. Fall protection, construction (29 CFR 1926.501)
  2. Hazard communication standard, general industry (29 CFR 1910.1200)
  3. Scaffolding, general requirements, construction (29 CFR 1926.451)
  4. Respiratory protection, general industry (29 CFR 1910.134)
  5. Control of hazardous energy (lockout/tagout), general industry (29 CFR 1910.147)
  6. Ladders, construction (29 CFR 1926.1053)]
  7. Powered industrial trucks, general industry (29 CFR 1910.178)
  8. Fall Protection–Training Requirements (29 CFR 1926.503
  9. Machinery and Machine Guarding, general requirements (29 CFR 1910.212)
  10. Eye and Face Protection (29 CFR 1926.102)

(Source: www.osha.gov/Top_Ten_Standards.html)

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Unguarded Shear Point on Force Tester Amputates Worker’s Finger

A worker was injured while testing gas springs similar to the type that hold the hatchback of an SUV open. The hazard that injured the worker was an unguarded shear point. The tester contained a mounting plate that was raised and lowered by a pneumatic cylinder.

The pneumatic cylinder lowered the mounting plate while the worker’s fingers were in the hazardous, unguarded shear point. Read More

Case Study: Fatality Servicing Unsupported Excavator Boom

A mini-excavator at a job site developed a leak at a hydraulic fitting at the base of the cylinder that raises and lowers the boom. A subcontractor foreman at the site raised the boom to search for the leak. The foreman found and attempted to tighten the leaking fitting. When he did, the fitting separated from the base of the cylinder, releasing the hydraulic pressure that held the boom aloft. The boom fell and the bucket struck a nearby superintendent for the general contractor.

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Testing As Part of Gas Appliance Incident Investigation

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Equipment and appliances supplied with fuel gases like natural gas, propane and butane are a common and convenient part of most of our lives.  Such devices as gas grills and ranges, ovens, furnaces, space heaters and water heaters usually perform without incident.  However, when they malfunction the potential for incidents such as fires and explosions, carbon monoxide (CO) poisoning and burn injuries may occur. These incidents may be due to design and manufacturing defects in the product, or improper installation or operation of the device.

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Defective Vertical Baler Causes Serious Crush Injury to Operator’s Arm

I recently worked on an interesting case involving a box baler. An employee of a butcher shop put some empty cardboard boxes in a vertical box baler and pushed the control switch to compact the boxes. After the 30 by 60 inch platen weighing 851 pounds returned to its raised position, the employee reached into the open space above the bottom door on the baler and began to clear cardboard from the bale tie slots in the bottom of the raised platen. Suddenly, and without warning, the steel pin attaching the platen to the raised hydraulic cylinder rod failed. The heavy steel platen fell and crushed his arm which was outstretched over the baler door into the compaction space.

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