Ensuring the safety compliance of an existing industrial facility often requires more than simply installing a protective guard or light curtain. In some cases, the safeguarding around a hazardous area may need a complete redesign, while allowing enough space for process operations, providing maintenance access and ensuring an ergonomic working environment for operators.
Thomas Constructions Mécaniques (TCM) took on this precise challenge for one of its customers, a European leader in the metallurgy industry, by designing, manufacturing, and installing a customised pit protection system to fit around its existing coil-handling equipment.
The facility comprises a pit and coil storage areas, with a trolley connected to a coil-lifting cylinder that moves through these zones. The protection system therefore had to secure this area while accommodating the various positions and movements of the existing equipment. The general project diagram identified the pit, the storage areas, the trolley and the coil-lifting cylinder, a fixed platform, a mobile platform, fixed guards, and a retractable metal floor.
As a special machine manufacturer, TCM’s brings invaluable expertise to these kinds of projects, where operator safety, existing mechanical systems, and operational constraints must all be taken into account.
The challenge: protecting the pit while allowing for the coil lifter’s movement
When safeguarding an industrial facility, the risks associated with an open pit near a work area must be addressed. However, permanently closing off the pit was not an option in this case, as the coil-handling system operates in part of this area.
A solution was therefore required to physically secure the pit, when necessary, while automatically freeing up the space needed for the process equipment’s movements.
This added another layer of complexity because TCM needed to integrate the solution into the existing system, rather than replacing this equipment. It was decided that the mobile platform should be driven by the coil-lifter trolley and cylinder. The design also allows the platform to be quickly detached using tools, so that the trolley can pass underneath and reach the hatch when lowered, providing access to the cylinder for maintenance.
PROJECT CHALLENGES
Safeguarding the industrial pit and storage areas; maintaining the operation of the existing coil lifter; allowing operators to pass through the protected areas; providing access to the cylinder for maintenance; and integrating the new protection system into the existing mechanical and electrical equipment.
From site measurements to design: developing a fully customised pit protection system
Before the manufacturing phase, it is essential to gain a detailed understanding of the existing facility.
TCM therefore began with a preliminary on-site survey to take precise measurements, followed by a system assessment before its teams started the design work. The project also included the manufacture and delivery of the various components, as well as on-site installation, final acceptance, and new technical documentation.
This approach is typical for machine safety compliance projects: the solution must be designed around the actual conditions on-site.
The aim of this project was not to design a protection system that functions independently of the machine, but rather to design a mechanical assembly whose movements integrate seamlessly with the coil lifter’s operation.
A fixed platform to create a protected access area
installed by TCM
A fixed platform to create a protected access area
The first component of the system is a fixed platform made of chequered steel plate. It covers the pit as well as the unused storage areas and incorporates a hatch that can be removed using tools to provide access to the cylinder for maintenance.
This platform can be seen in the photos of the completed facility as the large non-slip metal surfaces positioned around the access area. Its integrated design is deliberately robust and perfectly suited to the conditions of a metal production site.
A mobile platform driven by the existing machine
The next challenge was to create a protected area that must be either open or closed depending on the position of the coil-lifter trolley.
TCM developed a mobile platform that slides within the frame of the fixed platform. Its cantilevered design supports most of its weight, with additional support provided by the coil-handling trolley. More importantly, the platform does not require an independent actuator but is driven by the movement of the coil-lifter trolley.
The mobile platform moves over the pit in tandem with the coil-lifter trolley.
This intelligent design thus builds on the machine’s existing kinematics.
A retractable metal floor with hinged panels
Another solution was required for a different section of the pit.
TCM designed a retractable metal floor that operators can walk across. It consists of hinged panels guided by rollers that run along rails. This floor’s movement is also directly linked to the coil-lifter trolley.
Our design office developed this mechanical principle using a combination of panels, pivots, and rollers, ensuring that the floor covers the entire width of the pit.
In the completed facility, this series of yellow panels is clearly visible; when extended, they form a long, continuous chequered steel plate surface. When the area needs to be cleared, the panels fold up into a compact stack at one end of the pit.
A custom-made pit protection system specifically designed to fit around the existing machine, comprising a fixed platform, a mobile platform, a retractable metal floor with hinged panels and fixed guards, providing safe access for operators. The goal was not to install standard equipment around the existing process machinery, but to create a fully-integrated protection system.
Safety that goes beyond mechanical protection, providing controlled access to the area
The physical protection system for the pit is just one aspect of the solution. Controlled access to the protected area was also required.
An interlock switch was fitted to the gate, as well as a button for operators to open it and request access. The new electrical components have been integrated into the existing electrical cabinets.
It operates according to a key safety principle: the gate will only open when the coil-lifter trolley is in one of two pre-defined positions, thus preventing access to the protected area while the system is moving.
Ensuring the safety compliance of an existing facility therefore requires a comprehensive approach which takes into account mechanical design, operator access, automated systems, and maintenance.
From 3D design to on-site installation: end-to-end support from TCM
This project demonstrates the value of working with a single partner who can manage the entire process from start to finish.
Following the on-site survey, the TCM design office defined the concept and the various process movements required. The components were then manufactured before being delivered and assembled at the customer’s site. The contracted service covered the preliminary site visit, design through to installation, acceptance testing, and new technical documentation.
TCM applies this philosophy to other safety compliance projects, by developing a customised solution for each machine rather than installing a standard protection system.
The pit protection system is adapted to the machine’s different operational phases; the solution is seamlessly integrated into the existing equipment’s operations; the floor allows operators to move safely through the designated areas; access is provided for maintenance; the mechanical design is robust and perfectly suited to the industrial environment; and end-to-end project management was provided from the on-site survey through to installation.
Why choose TCM to ensure the safety compliance of your industrial machines?
Every machine has its own specific history, kinematics, production constraints, and maintenance requirements. Simply supplying safety components is often not enough to bring existing production facilities into safety compliance.
With its design office and manufacturing workshop, Thomas Constructions Mécaniques designs and manufactures customised solutions that fit seamlessly into your existing facilities. This approach enables TCM to manage all the mechanical, electrical, and functional aspects of a project, from design through to on-site installation.
Whether requiring pit guards, enclosures, mobile protection systems, interlocked access points, upgrades to existing machines or modifications to hazardous areas: TCM starts every project with a detailed analysis of the customer’s specific needs and process constraints.
TCM offers extensive expertise in industrial machine safeguarding and safety compliance, while also providing additional services: design of special machines, industrial maintenance, and retrofitting of production equipment.
Do you need to safeguard an industrial pit or bring an existing machine into safety compliance?
Standard safety solutions are not always enough to protect hazardous areas.
TCM will assess your facilities and then design, manufacture, and install a safety solution tailored to your specific equipment and production constraints.
Have you identified a safety risk associated with a pit, handling equipment, or a production machine? Do you need to install new safety equipment without replacing your existing system?
Contact us today to discuss your safety compliance project. Our design office will work with you to design a customised solution that meets the safety, operational, and maintenance requirements of your facility.