Service Engineers Training Guide v1 by Formation

FOREWORD

VIVAMUS ULLAMCORPER CONSECTETUR ORNARE. NAM LUCTUS ODIO SED EROS BIBENDUM, EGET ULTRICES METUS PHARETRA. NULLA MAXIMUS LIBERO AT MI FINIBUS, VITAE LOBORTIS MASSA ELEMENTUM. INTEGER PRETIUM JUSTO NEC MASSA VEHICULA ORNARE. DONEC UT TURPIS EGET NISL VENENATIS VEHICULA VITAE IN URNA. ETIAM MOLLIS ID MAGNA UT MAXIMUS. QUISQUE ELEMENTUM ARCU GRAVIDA FELIS IACULIS BIBENDUM. PRAESENT TINCIDUNT VELIT EGET MI GRAVIDA CONGUE. LEE BOWDITCH, COMMERCIAL AND COUNTRY DIRECTOR (UK & IRELAND)

CURABITUR IACULIS FINIBUS SEM 3 .................................................................................................. ULTRICIES FAUCIBUS LOREM 3 .................................................................................................. LOREM IPSUM DOLOR SIT AMET 3

EHS STATEMENT OF INTENT 3 .................................................................................................. SPEAK UP - LISTEN UP 3 .................................................................................................. THE HOUGHTON CARDINAL RULES 3 .................................................................................................. THE MAIN UK REGULATIONS FOR HEALTH & SAFETY 3 .................................................................................................. HAZARDS FACING SERVICE ENGINEERS 3 .................................................................................................. WHAT ARE THE OPERATIONAL HAZARDS AT YOURSITES? 3 .................................................................................................. APPROVE CORE PPE 3 .................................................................................................. ACCIDENTS - 4 CAUSES & S.T.A.R. 3 .................................................................................................. KMI REPORTING AND 1 CALL SYSTEM 3 .................................................................................................. JOB TASK RISK ASSESSMENT 3 .................................................................................................. 2 MINUTE RISK ASSESSMENT 3 .................................................................................................. PPE 3 .................................................................................................. GHS - WHAT IS GHS? 3 .................................................................................................. SDS 3 .................................................................................................. KEY LABEL ELEMENTS: GHS 3 .................................................................................................. SAFE STORAGE, HANDLING AND USE OF CHEMICALS 3 .................................................................................................. INCIDENTS & HAZARDS 3 .................................................................................................. SKIN CARE & THE CONTROL OF DERMATITIS 3 .................................................................................................. MANUAL HANDLING 3 .................................................................................................. DRIVER AWARENESS 3 .................................................................................................. TRANSPORT OF CHEMICALS IN CARS 3 .................................................................................................. CHEMICAL HANDLING & COSHH 3 .................................................................................................. SAFE USE OF BIOCIDES 3 .................................................................................................. HAZARDOUS WASTE 3 .................................................................................................. LITRE DRUM HANDLING 3 .................................................................................................. SUB-CONTRACTORS 3 .................................................................................................. WORKSTATIONS 3 .................................................................................................. BASICS OF MWFâ€™S 3

BRAND

EHS

WHAT IS THE ROLE OF A SERVICE ENGINEER 3 .................................................................................................. CUSTOMER PRE-CALL PREPARATION 3 .................................................................................................. SITE ARRIVAL â€“ CHECKING IN 3 .................................................................................................. JOB ESSENTIALS 3 .................................................................................................. TO DO THE JOB 3 .................................................................................................. SERVICE ENGINEER ROADMAP 3 .................................................................................................. FLUIDSUPPORT PACKAGES 3 .................................................................................................. ORDER OF SERVICE TESTING 3 .................................................................................................. REFRACTOMETER 3 .................................................................................................. CALIBRATION SHEET 3 .................................................................................................. CONCENTRATION 3 .................................................................................................. P/H TESTING 3 .................................................................................................. DIP SLIDES 3 .................................................................................................. TRAMP OIL VISUALISATION 3 .................................................................................................. TEMPERATURE, ODOUR AND APPEARANCE 3 .................................................................................................. CORRECTIVE ACTIONS 3 .................................................................................................. SITE VISUALISATION 3 .................................................................................................. BIOCIDE ADDITIONS AND MEASURES 3 .................................................................................................. CERTS AND ACCREDITATIONS 3

OVERVIEW 3 .................................................................................................. DASHBOARD & NAVIGATION 3 .................................................................................................. ADD REPORT TO DASHBOARD 3 .................................................................................................. MACHINES 3 .................................................................................................. MACHINE STATUS 3 .................................................................................................. REPORTS 3 .................................................................................................. FLUIDTREND SCHEMATIC 3

A DAY IN THE LIFE OF A SERVICE ENGINEER

FLUIDTREND

EXTERNAL & INTERNAL STOR AGE

AN INTRODUCTION TO METALWORKING FLUIDS TECHNOLOGY

EQUIPMENT

DRUM OR IBC STORAGE 3 .................................................................................................. POLYETHELENE SPILL PALLETS 3 .................................................................................................. STEEL SPILL PALLETS 3 .................................................................................................. BULK STORAGE TANKS 3 MIXING & DISTRIBUTION VENTURI MIXER 3 .................................................................................................. DOSATRON 3 .................................................................................................. FLUIDMIX 3 .................................................................................................. DISTRIBUTION PIPEWORK 3 TRE ATMENT & M AINTENANCE FREDDY VACUUMS 3 .................................................................................................. TRAMP OIL REMOVAL 3 .................................................................................................. FILTRATION 3 .................................................................................................. SEPARATION 3 ENVIRONMENTAL , HE ALTH & SAFETY MIST EXTRACTION 3 .................................................................................................. LEV TESTING 3 .................................................................................................. AIR MONITORING 3 .................................................................................................. SPILL MEDIA 3 COST RECOVERY BRIQUETTING 3 .................................................................................................. CENTRALISED SYSTEMS 3 WASTE TRE ATMENT EVAPORATION TREATMENT 3 .................................................................................................. VACUUM EVAPORATION TREATMENT 3

TECHNICAL APPLICATION

METAL CUTTING 3 .................................................................................................. PRIMARY FUNCTIONS OF A MWF 3 .................................................................................................. METALWORKING FLUID TYPES 3 .................................................................................................. NEAT OILS VS SOLUBLE COOLANTS 3 .................................................................................................. FACTORS AFFECTING NCO PERFORMANCE 3 .................................................................................................. THE MAIN FUNCTIONS OF A WATER BASED COOLANT 3 .................................................................................................. SOLUBLE COOLANTS 3 .................................................................................................. THE EFFECTS OF TRAMP OIL 3 .................................................................................................. THE EFFECTS OF SWARF AND FINES 3 .................................................................................................. THE EFFECTS OF MICRO-ORGANISMS 3 .................................................................................................. WATER QUALITY 3 .................................................................................................. PEOPLE 3 BASIC FLUID M ANAGEMENT BASIC FLUID MANAGEMENT 3 .................................................................................................. SUMP-SIDE TREATMENT 3 .................................................................................................. HEALTH AND SAFETY SKINCARE 3 METALWORKING FLUIDS APPLICATION GUIDE TERMINOLOGY 3 .................................................................................................. CUTTING OPERATION FACTORS 3 .................................................................................................. INCORRECT APPLICATION 3 .................................................................................................. FLUID APPLICATION 3 .................................................................................................. CHIP FORMATION 3 .................................................................................................. 205 LITRE DRUM HANDLING 3 .................................................................................................. SUB-CONTRACTORS 3 .................................................................................................. WORKSTATIONS 3 .................................................................................................. BASICS OF MWFâ€™S 3

CUTTING ACTION 3 .................................................................................................. CHIP GENERATION 3 .................................................................................................. METALCUTTING APPLICATIONS 3 .................................................................................................. SEVERITY OF OPERATIONS 3 .................................................................................................. SAWING 3 .................................................................................................. TURNING 3 .................................................................................................. DRILLING 3 .................................................................................................. TAPPING 3 .................................................................................................. REAMING 3 .................................................................................................. MILLING 3 .................................................................................................. CNC MACHINES 3 .................................................................................................. DEEP HOLE DRILLING AND BORING 3 .................................................................................................. BROACHING 3 .................................................................................................. GEAR MACHINING 3 .................................................................................................. GRINDING 3 .................................................................................................. HONING 3 .................................................................................................. MINIMUM QUANTITY LUBRICATION 3 .................................................................................................. ELECTRO DISCHARGE MACHINING 3 .................................................................................................. MACHINABILITY 3 .................................................................................................. TOOLS 3 .................................................................................................. FORMING, PRESSING AND DRAWING 3 .................................................................................................. RUST PREVENTIVES AND HE AT TRE ATMENT CORROSION 3 .................................................................................................. RUST PREVENTIVE COMPOSITION 3 .................................................................................................. PERFORMANCE ADDITIVES 3 .................................................................................................. COMPARING PRODUCT TYPES 3 .................................................................................................. RP TESTING AND MONITORING 3 .................................................................................................. HEAT TREATMENT & QUENCHANTS 3

STEEL - HARDENABILITY 3 .................................................................................................. STEEL TYPES 3 .................................................................................................. QUENCHING PROCESS â€“ 2 TYPES 3 .................................................................................................. EXAMPLE OF QUENCHING OPERATIONS 3 .................................................................................................. THE 3 PHASES OF COOLING 3 .................................................................................................. QUENCHING CURVES: INCONEL PROBE 3 .................................................................................................. EQUIPMENT FOR IMMERSION QUENCHING 3 .................................................................................................. QUENCH OILS AND POLYMER SOLUTIONS 3 HSE ISSUES HEALTH, SAFETY AND ENVIRONMENTAL ISSUE FOR METALWORKING FLUIDS 3 .................................................................................................. METALWORKING FLUIDS AND HEALTH 3 .................................................................................................. ENVIRONMENTALLY FRIENDLY METALWORKING FLUIDS 3 DISPOSAL METALWORKING FLUIDS DISPOSAL OPTIONS

DEVELOPMENTS AND FUTURE TRENDS COOLANT EVOLUTION 3 .................................................................................................. DEVELOPMENT 3

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

BR AN D

BR AND F L U I D E N GI N E ER S T R A I N IN G GU I DE FL UID FLUID ENGINEER ENGINEE S TR ARISN ITNRGAIGNUIINDE G G U I DE

B R A NDB R AN D

LOREM IPSUM DOLOR SIT AMET, CONSECTETUR ADIPISCING ELIT. SED TEMPUS SODALES PHARETRA. MAURIS AT LIBERO VEL ELIT PLACERAT. Lorem ipsum dolor sit amet, consectetur adipiscing elit. Sed tempus sodales pharetra. Mauris at libero vel elit placerat eleifend convallis sed metus. Praesent et ullamcorper dui, vel pulvinar turpis. Donec sapien est, efficitur vitae augue et, accumsan ultrices lectus. Integer quis ipsum ligula. Proin ut nibh hendrerit risus ornare pulvinar. Etiam

maximus lorem elementum a. Etiam auctor velit tortor, in

consequat, ex non efficitur euismod, augue enim

finibus libero faucibus sit amet. Nulla pellentesque, lectus

condimentum eros, id tincidunt libero felis vel tortor.

ac malesuada semper, lacus augue porta est, in eleifend

Praesent volutpat posuere nisl ut cursus. Aliquam

nunc felis mollis eros. Vivamus molestie massa eu quam

libero sapien, accumsan auctor est quis, bibendum

consequat, ut fringilla risus accumsan. Ut aliquet, odio

semper sem. Maecenas vitae tincidunt enim. Aliquam

in fermentum lobortis, magna augue lacinia lorem, in

erat volutpat. Nullam fringilla ac sem quis iaculis. In ac

lobortis felis dui ac massa. Integer mollis, justo quis mollis

convallis dui, a rhoncus felis. Cras hendrerit et nisi in

condimentum, nibh nunc ultricies diam, ut luctus lacus

sollicitudin.

ligula porttitor tellus.

Duis sodales consequat nisl, vel malesuada orci

Praesent et nisl commodo, posuere orci non, finibus

posuere vitae. Quisque nec purus eu tellus tristique

metus. Aliquam quis porta quam, nec facilisis sapien.

fringilla. Pellentesque condimentum sem lacus, ut

Aliquam ac erat id nisl tempor volutpat vel vel tellus.

LOREM IPSUM DOLOR SIT AMET, CONSECTETUR ADIPISCING ELIT. NULLAM HENDRERIT ORNARE DIAM. INTEGER PORTTITOR COMMODO EROS, NEC VOLUTPAT ARCU DIGNISSIM QUIS. NAM ACCUMSAN MAGNA VITAE VESTIBULUM VENENATIS.

JOHN SMITH, ROLLYS ROYCE

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

STYLE GUIDE

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adipiscing elit. \\

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COMPLIANT

COST EFFICIENT

PRODUCTIVE

IN BEST PRACTICE

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Lorem ipsum dolor sit amet.

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 SOLUBLE CUTTING FLUID  NEAT CUTTING OIL  METAL PROTECTION  DEGREASING & CLEANING  HEAT TREATMENT  FIRE RETARDENT & GENERAL LUBRICATION  FORMING

FL UID ENGINEER S TR A I N I N G G U I DE

B R A ND

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

EHS

E HS F L U I D E N GI N E ER S T R A I N IN G GU I DE FL UID FLUID ENGINEER ENGINEE S TR ARISN ITNRGAIGNUIINDE G G U I DE

EH S

EHS

THERE IS NOTHING WE DO THAT IS WORTH GETTING HURT FOR

The Fluidcare Operational teams have launched a programme of Information to accelerate a change in EHS performance. \\

It’s everyone’s job (supported by the EHS team)

We must engage the whole work force

It must become the way we do our jobs

We must avoid it becoming a “tick box” exercise

It must be reinforced with rigour

We must get to root cause & improvement

We must use KMI as it is a great enabler

We must focus on the most critical risks with the

Near miss reporting is critical

highest likelihood of occurrence

We Will, So Far As Is Reasonably Practicable, Ensure That: \\

Health and Safety is recognised as an integral function

to employees

of business performance \\

Adequate resources are provided to ensure that proper

Risk assessments are carried out and

made with regard to the facilities and arrangements

Systems of work are provided and maintained that are

for their welfare at work

safe and without risks to health \\

Arrangements for use, handling, storage, and transport of articles and substances for use at work are safe and without risks to health

The working environment of all employees is safe and without risks to health and that adequate provision is

periodically reviewed \\

The provision and maintenance of all plant, machinery and equipment is safe and without risk to health

provision can be made for health and safety \\

Where appropriate, health surveillance will be provided

The place of work is safe and that there is safe access to and egress from the work place and that monitoring activities are undertaken to maintain agreed standards

All employees are provided with such information, instruction, training and supervision as is necessary to secure their safety and health at work and the safety of others who may be affected by their actions

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

HEALTH AND SAFETY POLICY STATEMENT OF INTENT

EHS

Houghton PLC consider and recognise its duties to the health and safety of all employees, the self-employed or contractors who may be working either on behalf of Houghton PLC or close to our own employees, customer employees and members of the general public who may be affected by our activities. The Management at all levels regards the promotion

All employees have a duty of care under the Health and

of this Health and Safety Policy and all accompanying

Safety At Work Act to take reasonable care with regard

procedures as a prime objective of the business

to the health and safety of themselves and of others;

performance thereby ensuring, so far as reasonably

to make themselves aware of and to co-operate in the

practical, a safe environment for work is maintained.

implementation of Houghton PLC policy, procedures and all relevant statutory regulations/codes of practice, to

The main objective of this policy and subsequent

ensure a safe working environment

documents are to ensure that all company employees perform their respective duties without undue risk to either their own health or safety or to that of those around them. All levels of management are responsible for ensuring that this policy is fully implemented throughout all activities within Houghton PLC and for providing information, instruction and training as is necessary for the promotion of health and safety within the area of their responsibility. Co-operation of all employees at all levels is fundamental to the success of this policy. Houghton PLC expects all employees to have a mature attitude towards health and safety and not to involve themselves in any unsafe practice that may result in an accident. People are the most important asset of Houghton PLC. To fulfil both our legal and moral obligations, it follows that we will take care of their health and safety. Houghton PLC shall ensure that the content of all EHS related documentation is communicated to all persons in the organisation relevant to their area of work and shall

“I REGRET TO SAY THAT PEOPLE ARE STILL GETTING INJURED DURING THE COURSE OF THEIR DAILY WORK AND MYSELF, THE UK MANAGEMENT TEAM AND OUR EHS PROFESSIONALS BELIEVE WE NEED TO SPEED UP THE PACE OF CHANGE. ‘THE MAKE A DIFFERENCE TO SAFETY’ INITIATIVE HAS THE FULL SUPPORT OF MYSELF AND THE REST OF THE MANAGEMENT TEAM AND WE WANT TO RE-ENFORCE OUR COMMITMENT THAT NOTHING IN THIS BUSINESS IS WORTH GETTING HURT FOR. I HOPE YOU WILL SUPPORT THE ACCELERATION OF CHANGE AND PUT YOUR SAFETY FIRST.” STEVE MAYO, REGIONAL DIRECTOR EMEA NORTH HOUGHTON INTERNATIONAL

consult on EHS matters with all levels of the company.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

SPEAK UP – LISTEN UP Giving safety feedback means exercising my right and responsibility to speak up and warn somebody if I see something unsafe and have direct concerns about another person’s At-risk behavior. Speak up if it affects: \\

The individual’s safety

Your safety

Another employee’s safety

Getting safety feedback means:

Safety Feedback is about responsibility and respect.

Respect for yourself and caring for all others in an Organisation whilst reinforcing a culture of safe working practices.

What I’m doing is creating a danger to myself or someone else.

Somebody cares enough about me to Speak Up!

I need to Listen Up! and change what I’m doing

No matter how the other person approaches me or how they say it, if it’s about safety I need to listen

2 STEPS TO GETTING FEEDBACK

LISTEN

COMMIT

Focus on the message

Agree on a safer way

Get to the facts

Make the commitment to

Ask questions to understand (if needed)

HOUGHTON I N T E R N AT IO N A L

work safer \\

Follow it up

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

Don’t let Feelings Get in the Way: \\

We are responsible for:

The other person is acting responsibly to give you honest feedback

It is normal to feel challenged when someone corrects our behavior

Our own feelings

How we choose to respond

Remember feedback really means someone cares enough about you (about your personal safety)

Feedback can sound and feel like criticism

to speak up!

Constructive criticism will help you improve

3 STEPS TO GIVING FEEDBACK

ASK

Ask if you can discuss

COMMIT

your concerns \\

Find out why they are doing what they’re doing

Work together to find a

FOLLOW-UP

safer way \\

Get a commitment from them

Check back to make sure they are working safely

Don’t give up if they are not

Offer positive feedback if they are

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

THE HOUGHTON CARDINAL RULES

There are other EHS rules that must be followed; however, violation of a Cardinal Rule could subject you to disciplinary action up to and including termination for a first time offence At Houghton we are committed to creating safe workplaces for our employees and those working on our behalf and minimising the impact of our operations on the environment. For these reasons, we have established Cardinal Rules to reinforce workplace safety and the protection of the environment. Cardinal Rules are a handful of Environmental, Health and Safety (EHS) rules that, if violated, could potentially result in life or businessthreatening situations, including severe personal injury or damage to the environment. Due to the elevated risk associated with certain work procedures or tasks, we require the highest level of compliance with the Cardinal Rules.

INCIDENT REPORTING

BY-PASSING OF A SAFETY DEVICE

CONTROL OF HAZARDOUS ENERGIES

CONFINED SPACES

All employees will

No unauthorised or

Lock-Out/Tag-Out â€“ Must

Confined Space Entry â€“

accurately report all

intentional By-Passing

be applied to control

Permits must be used for

workplace injuries and

of a Safety Device.

any potential hazardous

all permit required entry.

environmental releases.

HOUGHTON I N T E R N AT IO N A L

energy sources.

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

THE SEVEN RULES APPLY TO ALL SITES OWNED BY HOUGHTON INTERNATIONAL AND ALL FLUIDCARE OPERATIONS.

WORKING AT HEIGHTS

HOT WORK

FALSE EHS INFORMATION

All Working at Heights

Hot Work – All employees must be aware of the potential

All employees will openly

– Must use approved

hazards and employ appropriate safety measures and

document and report all

access equipment

follow approved procedures.

relevant EHS information

and appropriate

and must not falsely

fall restraints.

report EHS issues.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

THE MAIN UK REGULATIONS FOR HEALTH & SAFETY

The Health & Safety at Work Act 1974 – requires

the business owner to carry out actions that are

2002(COSHH) – assessment of all substances in the

reasonable and practicable to protect the workforce

workplace which are or may be Hazardous to Health

The Management of Health and Safety at Work Regulations 1999 – strict safety regulations with an approved code of practice which require full

Manual Handling Operations Regulations 1992

Personal Protective Equipment at Work Regulations 1992 (PPE)

compliance \\

The Workplace (Health, Safety & Welfare) Regulations

environment, safety, facilities & housekeeping

machinery & equipment used in any task

Health & Safety (Display Screen Equipment Regulations 1992 -DSE

Provision & Use of Work Equipment Regulations 1998 -PUWER – covers the safe provision and use of

Lifting Operations & Lifting Equipment Regulations (LOLER) 1992

1992 – apply to the premises & the cover the workplace

Control of Substances Hazardous to Health

Reporting of Injuries, Diseases & Dangerous Occurrences Regulations (RIDDOR)

IT SHALL BE THE DUTY OF EVERY EMPLOYER TO ENSURE, SO FAR AS IS REASONABLY PRACTICABLE, THE HEALTH, SAFETY AND WELFARE OF ALL EMPLOYEES

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

THE MAIN UK REGULATIONS FOR HEALTH & SAFETY -THE HEALTH & SAFETY AT WORK ACT 1974 Further duties extend this requirement to include others such as Contractors who may still be affected by the work undertaking \\

Safe plant and systems of work

Safe place of work including access and egress

Safe use, handling, transport, storage of substances

Safe working environment with adequate

and articles \\

Provision of information, instruction & training

welfare facilities \\

A written safety policy if more than four employees

THE WORKPLACE (HEALTH, SAFETY & WELFARE) REGULATIONS 1992 – EMPLOYERS RESPONSIBILITY These state that your premises should not be, or create, a risk to your workforce. This is not restricted to the building itself but covers four main areas: \\

Working Environment – includes temperature,

Facilities – must be suitable and sufficient lavatories,

ventilation, lighting, workspace dimensions &

washing facilities & changing areas together with

space, suitability of workstations, seating & outdoor

storage areas & lockers for clothing. Adequate rest

workstations

facilities & areas for eating & drinking. Drinking water must also be provided

Safety – safe passage for pedestrians and vehicles, windows being safe to open or close, doors/floors/

Housekeeping – workplace must be kept clean &

ceilings & walls made of safe material, safety devices

maintained at all times. Spillages must be cleaned up

on doors, gates & escalators, floors safely constructed

immediately and provision must be made for removal

& free from slips, trips & obstructions, dangerous

of waste material. You must keep housekeeping, repair

substances, falls from heights & falling objects must

& maintenance records

be prevented by guards or safety rails. Warning signs must be placed where necessary

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

THE PUWER REGULATIONS 1998 â€“ EMPLOYERS RESPONSIBILITY These state that in the course of carrying out your job

you must be provided with machinery & equipment that is safe to use. This includes everything from a small screwdriver to a major piece of manufacturing or

maintenance/repair logs) \\

controls

Always consider the workplace and user risk before

Reduce the danger caused by specific hazards

purchasing new equipment

Ensure the stability of the equipment

Provide adequate training, information & instruction on

Provide adequate lighting in the work area

Make warnings and markings clearly visible

the equipment \\

Protect the user from dangerous parts of the machinery by fitting guards and emergency stop

process plant equipment; \\

Ensure the equipment is properly maintained (keep

Keep records of all training undertaken â€“formal, internal and toolbox talks

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

THE MANAGEMENT OF HEALTH & SAFETY AT WORK REGULATIONS 1999 –EMPLOYERS RESPONSIBILITY \\

Carry out suitable Risk Assessments of the risks

Make arrangements for the safety of employees

to the Health & Safety of the employees. Further

of other companies onsite & provide appropriate

assessments must be conducted if a change/incident

instructions and information

occurs \\

Provide safety training at induction stage or upon

Record the arrangements for the Management of

transfer to a new role, area or when equipment is

Health & Safety

introduced

Employ competent people to carry out work duties

Ensure contacts with external services are available – First Aid, medical care etc

Provide Health & Safety information to all employees

Keep a record of all of the above

Keep a record of all training undertaken of all employees

After an accident, the employer is required to complete an accident investigation & record the findings

EMPLOYEES ARE REQUIRED TO REPORT ANY SHORTCOMINGS IN SAFETY ARRANGEMENT TO THEIR EMPLOYERS

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

HAZARDS FACING SERVICE ENGINEERS – NEW TO THE ROLE \\

Lack of experience of working in a new industry or workplace

May ignore warning signs and rules, or cut corners

Literacy and numeracy levels must be commensurate

Lack of familiarity with the job and the work environment

Reluctance to raise concerns (or not knowing how to)

Eagerness to impress workmates and managers.

May not recognise hazards as a potential source of danger

May not understand ‘obvious’ rules for use of

with the role \\

General health and physical capability suitable for the role

Relevant work experience, competence or defined training at induction phase

Familiarity with the site, scope of work and the working environment

equipment \\

May be unfamiliar with site layout -especially where site hazards may change from day to day

FOLLOW THIS SIMPLE RULE AND REDUCE THE RISK OF SLIP, TRIP AND FALL INJURIES: IF YOU DROP IT, PICK IT UP IF YOU SPILL IT, WIPE IT UP LOOK WHERE YOU ARE GOING GO WHERE YOU ARE LOOKING

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

HAZARDS FACING SERVICE ENGINEERS â€“ SITE VISITS \\

Visiting multiple sites

Exposure to varying levels of Hazardous chemicals

Limited site knowledge â€“personnel, facilities &

Exposure to machinery & processes

Exposure to metalworking fluids & process chemicals

Safe access & egress for Testing, Samples & Stock

processes \\

Infrequent visits and unknown changes happening onsite

Different Hazards at different sites

Differing levels of management of Hazards by customers

Differing levels of management of contractors

Exposure to varying levels of Hazardous working

checks \\

Potential Lone working

Self-management of working day, time onsite & schedules

Driving to, from, on & between sites

environments

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

HAZARDS FACING SERVICE ENGINEERS - SLIP, TRIPS & FALLS Be aware of the environment and always focus on the task.

Stop, Think, Act & Review “HAVE I DONE THIS TASK BEFORE?”

“HAVE I GOT THE RIGHT PPE?”

“IF SO, HAVE THINGS CHANGED?”

“AM I FEELING FRUSTRATED, ANGRY OR TIRED?”

“WHAT CAN HURT ME, DURING THIS TASK?”

“AM I UNDER PRESSURE TO RESPOND AND TO ACT QUICKLY?”

“AM I PUTTING MYSELF OR OTHERS AT RISK?”

What can i do to prevent slips, trips, and falls?

WORK AREA

Wear appropriate

WET FLOORS

slip-resistant shoes. \\

Slow down to negotiate turns,

PARKING LOT AND GROUNDS

Clean up wet areas and spills immediately.

thedanger of wet surfaces

limited visibility.

when mopping. \\

Watch for curbs and potholes whenmoving between vehicles.

Assume there is ice if the temperatureis close to freezing;

Use caution in areas where wet

clean, clear,and well lit for you

floorsare likely: entrances, rest

and your visitors.

rooms, andmopped floors.

HOUGHTON I N T E R N AT IO N A L

Stay alert for uneven surfaces.

Make sure signs warn others of

corners,obstacles, and areas of

Keep workspace and walkways

slow down and takeshort strides.

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

Who is Responsible for Preventing Slips, Trips and Falls?

H UM AN FACTO R S T R AI N I N G ENCOUR AGES EMP LOYE E S TO TAKE PER SO NAL RE SP O N S I BI LI TY AND BUILD SAFE TY THAT, COMBINED W ITH A CO MPA N Y â€™S RESPONSABILIT I E S, CAN DR ASTICALLY RE D UCE THE FREQUENCY O F S LI P, T RI P A N D FALL ACCIDENTS.

C OMPA NY R E SP ON S A B IL IT Y

P E R S ON A L R E SP ON S IB IL IT Y

Provide training

Actively participate in training

Properly maintain work sites

Report maintenance issues

Develop policies/procedures

Follow policies/procedures

Invest in quality housekeeping products

Follow housekeeping requirements

Develop company safety culture

Participate in safety culture

Provide regular reminders on safe walking habits

Analyze and improve walking habits

Improve off-the-job safety with human factors training

Apply lessons from human factors training when off the job

Stop, Think, Act & Review

STAIRS

\\ \\

Take only one step at a time.

CORDS

Keep one hand free to grasp

Limit your load and make sure

other objectsto extend across a walkway.

the handrail. \\

Do not allow electrical cords or

LADDERS

chair, table,bucket, or box. \\

Tie up any cords that might pose a trip hazard.

your vision is not obstructed.

Tape down or secure cords

Stand on a ladder instead of a

Use the correct ladder for the job.

Never step on the top platform of anyladder, including a stepladder.

temporarilylocated in traffic areas.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

HAZARDS FACING SERVICE ENGINEERS â€“ SITE EMERGENCY Employer Requirements \\

The primary requirement, in an emergency, is that everyone can be evacuated to a place of safety

Information on Emergency arrangements should be made available to all employees, all contractors and all visitors in their care, tested at periodic intervals and appropriate training and instruction provided

If a fire or emergency occurs people need to be able to escape quickly in an orderly manner and reach a place of safety

You need to know \\

How to raise the alarm

The system of giving warning in the event of an Emergency

Escape routes to Emergency and Fire exits

The Assembly point where you can be accounted for

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

HAZARDS FACING SERVICE ENGINEERS â€“ MANUFACTURING Will you be performing tasks where you may be exposed to hazards from:

Chemical liquids

Chemical gases/

Airborne contaminants

vapours

Radiation

Chemical dust

Hot Works/Sparks

Acid or Caustic liquids

High/Low

Metal swarfor Fines

Ejected Metal

Molten metal

Temperatures \\ \\

High humidity Noise

Vehicle movement

Chemical Lines

Access & Egress

Electrical Hazards

CNC/Manual MC`s

Confined spaces/Pits

Robotic Cells

Overhead cranes/

Automated Lines

Furnaces

Forges/Presses

Hot Washers

Gantry work \\

Maintenance/Building work

Service/Contractors

HAZARDS FACING SERVICE ENGINEERS AWARENESS Will you be performing tasks where you may be exposed to hazards from:

Absorption of harmful substances

Irritants

Corrosives

Severe cuts

Lacerations

FL UID ENGINEER S TR A I N I N G G U I DE

Abrasions

Punctures

Chemical Burns

Thermal Burns

Temperature Extremes

EH S

WHAT ARE THE OPERATIONAL HAZARDS AT YOUR SITES? Employer Requirements

Hand Injuries (Cuts, Swarf, Chemical)

What operations require Lock-out/Tag-out?

What operations require what type of glove?

What systems are in place?

What storage is there for gloves between tasks?

Do you fit your own locks?

Do you know what glove to use?

Do you know how to put on and remove gloves safely

Working at Heights \\

Safe fixed Access?

Equipment?

Is it adequate?

Is it safe to use?

Is fall restraint required?

Confined Spaces \\

Have they been assessed?

Are they permit or non-permit required confined spaces?

What safety arrangements are required?

What are the rescue arrangements?

Housekeeping \\

Did you know most incidents come down to poor housekeeping?

Do you remove or report spills â€“think twice before entering a cluttered area?

Hazardous Chemicals \\

What are the hazards?

How should they be stored?

What decanting methods should be used?

How should it be safely transported?

What PPE? What else is required?

Restricted Access \\

Are you struggling to get in/to the workplace?

Has this been reported properly to Houghton & Client

Situation addressed?

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

APPROVED CORE PPE

Disposable Body Protection

Polypropylene Lightweight Coverall

Pal CPE Covershoes

Arco Mob Caps

Rubber Apron

PKN/R51 Sky Fire Knotted Hairnet

Hearing Protection

Peltor Optime III Overhead Ear Muffs SNRR35

Peltor Optime III Behind Head Ear Muffs SNR 35

Peltor Optime III Helmet Mounted Ear Muffs

3M Banded Ear Plugs SNR26

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

APPROVED CORE PPE

Eye & Face Protection

Centurion Connect Visors & Carriers

Centurion Connect Chin guard & Chin Guard Visors

Visitor Overspec / Eyeshield

Arco Clearview Eyeshield

Protector Face Shield Acetate Visor FL800A

Head & Ear Protection

Arco Champion Plus Safety Helmet

Centurion Connect S41 Helmet Mounted Baltic Ear Muffs SNR25

HOUGHTON I N T E R N AT IO N A L

Centurion Connect S42 Aegan Helmet Mounted Ear Muffs

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

APPROVED CORE PPE

Hand Protection

Arco Disposable Nitrile Gloves \\

Excellent abrasion performance

Good blade cut resistance and very good grip properties due to the nitrile micro finishing of the coating

Flexible and comfortable

Coating resistant to residual oils and greases present on handled parts.

Foot Protection

Steitz Safety Shoe

Steitz Safety Boots Black

Arco Tan Lined Safety Rigger Boots c/w midsole

Safety Plus Wellingtons

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

ACCIDENTS - 4 CAUSES, STOP & THINK AND S.T.A.R Prevention is the goal you must:

I DIDN’T THINK

Report accidents and incidents immediately

Take immediate emergency response measures as appropriate

I DIDN’T SEE I DIDN’T KNOW I DIDN’T ASK

Identify and report hazards to reduce future incidents

STO P A N D T HIN K BE F OR E YOU AC T

IT IS YOUR DUTY to follow the EHS Cardinal rules, Global mandates & Site Safety Rules.

IT IS YOUR RESPONSIBILITY to take reasonable care for your own safety and the safety of people working around you.

YOU ARE RESPONSIBLE FOR EVERYTHING THAT YOU DO AND ANYTHING YOU DON’T DO – If you create a hazard then you are responsible.

ALWAYS BE AWARE OF THE SITE SAFETY RULES, PROCEDURES & SAFETY ARRANGEMENTS

TAKE REASONABLE CARE – Always use and store materials, equipment and tools responsibly. As soon as you have finished with items then put them away appropriately & never leave them where they could cause an injury to someone else.

NEVER FOOL AROUND or play practical jokes in the workplace. Horseplay can be dangerous and you could injure yourself or cause someone else to be harmed.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

HAVE A S.T.A.R. BEFORE EACH JOB

STOP

THINK

Report near-misses – This will prevent

ACT

future accidents \\

Never try to perform work that you are not qualified to

REVIEW

Always report any accident or injury however slight. Use the accident book & KMI.

Always be aware of potential health and safety hazards

do or have not been properly trained to undertake. - If

and report any potentially dangerous situations to your

you are in doubt just ask!

supervisor or manager

Always Raise a Concern if \\

You have insufficient safety equipment

- PPE, Access equipment etc. \\

You have inadequate instructions or training

You do not have access to safety information (SDS, COSHH assessments or risk assessments).

- Ask yourself - “is this my job?”

You are being asked to do something that you feel is unsafe

As part of your daily onsite duties you must always be responsible and accountable: \\

Follow health and safety rules.

Be aware of emergency procedures.

Take part in any drills and know where emergency equipment and exits are.

signs, notices or instructions, blocked exits or escape routes \\

Always follow safe operating procedures.

Never take chances or shortcuts.

Immediately notify your supervisor or manager of any

Use accident, near-miss & hazard reporting procedures

cleaning and storing. \\

Report damaged or misused safety & protective equipment

Always use protective equipment and clothing in the correct manner & follow approved practices for

Notify management of missing or vandalised safety

Have the right to refuse to do a task if you believe it is unsafe.

misuse or lack of any equipment, missing machine guards and/or safety devices

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

KMI & NEAR-MISS REPORTING It is the first of our EHS Cardinal Rules – WHY?

We want to have a SAFE workplace.

We want to INVESTIGATE incidents

We want to share LESSONS

If incidents and hazards are not

to determine where we can improve

LEARNED from our investigation

reported, we cannot correct the

our Management Systems to

with other Houghton sites to

situations.

prevent recurrence

prevent any recurrence on any

SAFE

INVESTIGATE

LESSONS LEARNED

other site

AN INCIDENT is any unplanned event which typically results or can result in injuries, illnesses, chemical releases to the environment or property damage. Incidents can be classified as the following: \\

ACCIDENT – An event that results in unintended harm or damage.

WHO IS YOUR SAFETY OFFICER? - YOU ARE!

NEAR MISS – An event that could have, but did not

You are in the best position to assess if the tasks you

result in unintended harm or damage.

conduct are being done safely – If in doubt, ASK. Your

Unsafe conditions such as spilled coffee or water

EHS department is here to advise you, but they cannot

on the floor should not be reported as near misses,

ensure your safety – you need to raise concerns so that

these are hazard identifications.

appropriate safety controls can be implemented.

Wherever practicable, immediately report any accident or

(Remember you are a contractor on site, the customer

injury, however slight, and always within 24 hours. Action

may fill in their accident book but we need one for

taken at this stage will help prevent future accidents.

Houghton’s records as well).

Use the accident book and complete the initial report on

Always use the following format on KMI to report the initial

the KMI system – this will automatically alert EHS.

Incident.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

HAZARD IDENTIFICATION - TWO TYPES

An existing or potential condition which by itself or

An observable action that increases risk and if not

combined with other conditions has a high probability of

corrected has a high probability of leading to an accident

UNSAFE/SUB-STANDARD CONDITION

AT-RISK BEHAVIOUR

resulting in an accident

ACCIDENT reported by the SITE MANAGER after the injured person is dealt with. Inform the Line Manager, EHS & Customer & always complete the Accident Book and

ALL ACCIDENTS SHOULD BE REPORTED AS SOON AS REASONABLY PRACTICABLE AND WITHIN 24 HOURS.

KMI Report.

NEAR MISS reported by the person who witnessed the near miss to the Site Manager who will report on KMI.

HAZARD IDENTIFICATION reported by the person who identified the hazard to the Site Manager who will report on KMI.

ON <DATE>, AT <WHAT TIME> A <WHO (JOB TITLE, NO NAMES)> WAS <DOING WHAT, WHERE> WHEN <WHAT HAPPENED> CAUSING <WHAT CONSEQUENCES>

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

ALWAYS REMEMBER

YOU NEED TO TAKE CARE OF THE INJURED PERSON \\

Provide First aid & if a hospital visit is required this MUST be escorted.

YOU NEED TO REPORT THE INCIDENT

Line manager, EHS, Customer

Accident book and Houghton EHS department via KMI system

WE NEED TO FIND OUT WHAT WENT WRONG AND WHY? \\

Gather evidence, photographs, statements etc.

WE NEED TO PREVENT SIMILAR INCIDENTS \\

Take preventative measures and use lessons learned for incident sharing

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

1 CALL 1 Call is the automated system that you will always use in

Enter the script as defined below – YOU MUST USE THIS

the event that an INCIDENT OF CONCERN occurs. A full

FORMAT AT ALL TIMES FOR ALL INCIDENTS

list is provided on the following page. In the event that this happens you will follow the procedure below.

your job title here) at the (enter location name, location type, and country). I am calling to report an incident of

Open your internet browser and type:

concern. On <enter DATE here>, at <enter WHAT TIME here>, an <enter WHO (Job Title, no name)> was <enter

https://secure.onecallnow.com/Login/Login.aspx?Svc=1

Doing WHAT, WHERE> when <enter WHAT Happened> causing <enter WHAT Consequence>.

From the login page, \\

type in the GROUP ID - 257658

and password – safety2123

and click the ‘LOGIN’ button.

Hello, this is (enter your name here). I am the (enter

Click the Next button

Then Select your contacts – Subgroup ‘UK’

Click the Next button

From the ‘Send Your Message’ screen, select, the SEND button.

From the main page, select the NEW button inside of

Your message will automatically be delivered to the phone

‘Send a Message’.

numbers and email addresses of the Leadership team in

Select your call type(s) – Phone & Email

Note: By default Phone checkbox is selected – Select Email checkbox too.

FL UID ENGINEER S TR A I N I N G G U I DE

your area (Provided you selected the correct Subgroup)

Note: The delivery date and time is selected by default – DO NOT CHANGE THESE

EH S

INCIDENTS OF CONCERN Safety \\

Environment

Work related fatality to a Houghton International Inc.

employee or contractor \\

Work related injury (requiring more than basic first

International Inc. product or waste \\

of hazardous materials or waste to the

contractor

environment exceeding

Work related motor vehicle accident involving a

1 Gal/3.78 litres

Air or water release, or suspected release to the

Vehicle accident of a common or third-party carrier

environment, exceeding an authorised or required

hauling Houghton International Inc. product

permit limit \\

Work related fatality

Work related illness of a Houghton International Inc.

Miscellaneous

employee or contractor

Fire causing damage in excess of ÂŁ6,000 ($10,000)

Chemical exposure of Houghton International Inc.

Security event (Media event involving a Houghton

employee or contractor requiring medical attention

Any release that by-passes an environmental control system

Health

Loss of primary containment (LOPC) spill or release

aid) to a Houghton International Inc. employee or

Houghton International Inc. employee or vehicle \\

Any spill release during transportation of any Houghton

HOUGHTON I N T E R N AT IO N A L

International Inc. facility)

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

JTRA JOB TASK RISK ASSESSMENTS As part of a ‘World-Class’ EHS culture across Houghton we

A risk assessment is a vital element for health and safety

need to ensure that all Houghton employees are able to

management and its main objective is to determine the

conduct their duties safely.

measures required to comply with statutory duty under the Health and Safety at Work Act 1974and associated

Across Houghton globally there have been reported

regulations by reducing the level of incidents/accidents.

incidents due to reliance on PPE, rather than assessing & implementing higher level control measures.

A risk assessment will protect your workers and your business, as well as complying with law. As for when to do

The Job Risk Assessment tool has been selected for

a risk assessment it should simply be conducted before

this purpose and it is to be used to evaluate all activities

you or any other employees conduct some work which

conducted by Houghton employees globally.

presents a risk of injury or ill-health.

The process involves assessing the risks associated with

A person from your organisation needs to attend risk

every task every one of our employees is required to do as

assessment trainingas it will ensure that this person is

part of their contractual core duties and then conducting

competent within your organisation and will gain abilities

a risk assessment against it.

such as hazard identification, ability to categorise and evaluate risk(s). These abilities will allow a ‘suitable and

We then put into place barriers of protection so that our

sufficient’ risk assessment to be conducted within your

employees do not get hurt.

own organisation.

The JTRA for a manned Fluidcare site is specific to the core duties conducted on that site. The JTRA for a Service Engineer is specific to the core duties conducted by the person at all sites.

“….A CAREFUL EXAMINATION OF WHAT, IN YOUR WORK, COULD CAUSE HARM TO PEOPLE, SO THAT YOU CAN WEIGH UP WHETHERYOU HAVE TAKEN ENOUGH PRECAUTIONS OR SHOULD DO MORE TO PREVENT HARM….”

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

JTRA –JOB TASK RISK ASSESSMENT There are no fixed rules on how a risk assessment should be carried out, but there are a few general principles that should be followed. Five steps to risk assessment can be followed to ensure that your risk assessment is carried out correctly, these five steps are:

In order to identify hazards you need to understand

Once you have identified a number of hazards you need

the difference between a ‘hazard’ and ‘risk’. A hazard is

to understand who might be harmed and how. Consider

‘something with the potential to cause harm’ and a risk is

all employees and others such as cleaners, visitors,

‘the likelihood of that potential harm being realised’.

contractors, maintenance workers, young workers,

IDENTIFY THE HAZARDS

Ignore the trivial and concentrate on significant hazards which could result in serious harm or affect several

DECIDE WHO MIGHT BE HARMED AND HOW

trainees, new and expectant mothers and members of the public.

people. Hazards can be identified by using a number of different techniques such as walking round the workplace, observing the task and asking your employees.

After ‘identifying the hazards’ and ‘deciding who might

Your findings should be written down it’s a legal

be harmed and how’ you are then required to protect

requirement where there are 5 or more employees;

the people from harm. The hazards can either be

and by recording the findings it shows that you have

removed completely or the risks controlled so that the

identified the hazards, decided who could be harmed

injury is unlikely.

and how, and also shows how you plan to eliminate the

EVALUATE THE RISKS AND DECIDE ON CONTROL MEASURES

RECORD YOUR FINDINGS AND IMPLEMENT THEM

risks and hazards.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

JTRA –JOB TASK RISK ASSESSMENT \\

As part of our objective to maintain a ‘World-Class’ EHS culture across Houghton we need to ensure that all Houghton employees are able to conduct their daily

Apply the 5 Steps to Risk Assessment

If it is a C Rating then the risk is minimal with the current levels of control suitable

activities safely and without risk of harm \\

The Job Task Risk Assessment tool has been selected

independent levels of control in order to eliminate or

and it is used to evaluate all activities conducted by

minimisethe risk

Houghton employees globally \\

The JTRA process involves assessing the risks

of control would fail

your contractual obligations We then conduct a risk assessment & review against that activity

Then we do a PPE assessment, to identify the appropriate PPE needed in case the independent level

associated with each task you undertake as part of

If the risk is an A or B, then we must put in place

We can then implement these multiple levels of protection so that our employees do not get hurt

REVIEW YOUR ASSESSMENT AND UPDATE IF NECESSARY You should never forget that few workplaces stay the same and as a result this risk assessment should be reviewed and updated annually, after an incident onsite or as a result of changes in Legislation.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

JOB TAKE RISK ASSESSMENT PROCESS

Management of Change, Pre-Startup Safety Review, Planning, Goals

Job Task Risk Assessment Process

Identify Responsible Parties

Injury / Illness History

Establish a Priority

Documents (Batch Ticket, MSDS, Work Orders)

Perform Hazard Assessment

Training

1. Define Routine and Task Needs

Interview

2. Identify Hazards Safe Working Procedures & Controls

Observation

3. Corrective Actions

Training and Communication

Employee-SupervisorManager Responsibilities

Follow-up

Process Assessment

Record-keeping

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

2 MINUTE RISK ASSESSMENT Job Task Risk Assessments are available for all

If you can answer “YES” to all the questions it is safe

contractual core duties. However, there may be

to continue.

occasions when you are asked to perform a one off task or activity that has no Risk Assessment. Alternatively

If you answer “NO” to any question then you need to stop,

there may have been a significant change to an existing

assess and report your concerns.

circumstance or JTRA. The document can then be used to identify what needs to In this case you can use the 2 Minute Risk Assessment

be done to make the activity safe to undertake.

tool but always notify your Manager, as the task may be out of the core Contractual duties and not our

Any “NO” responses must also be considered for entry

responsibility.

onto the KMI system.

The Two minute Risk Assessment tool - is a simple check sheet to quickly assess if an activity can be performed safely.

REFER TO YOUR SITE SPECIFIC COLLECTION OF JTRA`S AND STANDARD OPERATING PROCEDURES FOR EHS INFORMATION APPLICABLE TO YOUR SITE. FOR NON ROUTINE TASKS REFER TO THE ‘2 MINUTE RISK ASSESSMENTS’ PROCEDURE.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

2 MINUTE RISK ASSESSMENT

Name

Date

Task

Is there a safe working procedure/Risk assessment

Have you and the workgroup read and

for the task?

understood it?

Yes

If there is no safe working procedure/ risk assessment for the task

Yes

Before starting work Do you have the correct permits/authorisation for

Do you understand all of the hazards/risks of the task? Yes

Have you taken steps to eliminate the risks? Yes

Have you the correct tools and equipment?

the work? Yes

Are you wearing the correct PPE for the task? Yes

Is everyone, who needs to be, aware that you are carrying out the work?

Yes

No Yes

Have you been trained to carry out the task? Have you ensured that nobody could be harmed by Yes

anything that can move? i.e. isolate, immobilise any equipment. Yes

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

If lifting equipment or mobile plant is to be used

Before starting work Have you ensured that the floor area is clean and the work

Are you trained in the use of the equipment? Yes

area free of obstacles? Yes

Do you know the weight to be lifted? Yes

Is the load within the SWL of the equipment? Yes

Is the lifting equipment correctly tagged and in compliance?

If the work is at height or adjacent to unguarded openings Have you ensured there is no risk of falling by use of barriers, railings or harnesses, etc?

Yes

No Yes

Does the crane operator have full visibility of the work area? Yes

If a forklift is to be used, have the pre-use checks been conducted? Yes

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

JTRA â€“ JOB TASK RISK ASSESSMENT As per the original Fluidcare Risk Assessment process â€“we will determine the risk rating using the formula; Severity of likely injury x Likelihood of accident occurring

F R EQUENCY

SEV E RI T Y

Employees No injury/illness with either no treatment or one requiring first aid treatment only.

Employees Injury/illness requiring medical treatment or restricted duty/job transfer - no days away from work.

Employees Injury/Ilness with days away from work. Multiple injuries/illness.

Employees Fatality, long-term health impact, permanent disability.

Environmental Release event not resulting in discharge offsite.

Environmental Release event not resulting in discharge offsite but a potential need to notify external persons or affecting regulatory.

Environmental Off-site release event with no discernable environmental impact, but requiring notification to external persons.

Environmental Off-site release with impact to soil, groundwater or drinking water requiring remediation.

Event is considered extraordinarily unlikely to occur

Unlikely to occur again at this facility, but has occured elsewhere in industry/ Houghton

Expected to occur or has occured one or more times at this facility/Houghton

Expected to occur or has occured one or more times per year at this facility/ Houghton

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

M OST EF F ECTI VE

H IE R A R C H Y OF C ONT R OLS HI E R A RCHY

E X A MP L E S

E LI M I N ATI O N

Remove the risk entirely - most preferred option \\

Design or re-engineer job to eliminate physical, chemical, biological and ergonomic hazards

S UBSTI TU T I O N

Use Methods, tools, material, equipment, etc. that have a lower inherent hazard

E N G I N E E RI N G

LE AST E FF E CTI V E

A DM I N CO N TRO LS

PERSONAL P ROT E CT I V E E QU I P ME N T

FL UID ENGINEER S TR A I N I N G G U I DE

Substitute for less hazardous material

Reduce intensity of energy

Provide engineering solutions to the risk \\

Ventilation systems

Mechanical lifting arrangements

Machine guarding

Safety interlocks

Secondary containment

Fall protection e.g. catwalks with guardrails

Establish or implement procedure or practice that reduces the risk \\

Job Task Risk Assessments

Leadership engagement

Safety inspections

Additional training

Purchasing controls

Preventive maintenance

Housekeeping

Job rotation

The last line of defence -least preffered option. PPE failure will immediately expose to hazard \\

Appropiate for hazard and regulatory compliance

Eye, head, respiratory, foot, hearing, whole body

Lone worker alarms

Personal monitors

EH S

PERSONAL PROTECTIVE EQUIPMENT - PPE Hazard assessment & Controls \\

Look for all types of hazards –especially those that

and in sight

can be changed, can change or cannot be eliminated (stairs, gravity, moving equipment, etc.) as they increase the need for PPE \\

Keep those hazards that can’t be eliminated in mind

For those hazards you identified above that can change or can’t be eliminated, you’ll need to address them with proper PPE selection and procedures

Eliminating or controlling hazards with engineering or job controls should be your first priority to eliminate or minimize exposure to the hazards.

PPE Selection & Training \\

Company reasons (UK regulations, condition of employment, EHS)

Personal reasons (for your welfare, health, family, co-workers)

Hazards and risk potential

Customer requirements

Inspection

Putting on, adjusting fit and taking off

Storage and cleaning

Personal Protective Equipment - PPE \\

Eye protection

Hand protection

High Visibility

Face protection

Foot protection

Chemical resistant

Respiratory protection

Approved PPE

Fire retardant

Hearing protection

Long sleeves

Anti-static

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

Management, Assessment & Training \\

Understanding and support of the Company &

Regular and consistent enforcement by EHS Team & Support Team

Customer PPE policies \\

Setting an example at all levels at all sites

Scheduling time for putting on, taking off, cleaning & storing PPE

accident reports. \\

Suitable conditions and space for storage of PPE

Checks on condition of existing PPE

Provision of new PPE as required

Take part in EHS Audits

Monitor with observations, Hazard ID`s, near-miss &

Re-evaluate annually or when a job changes, new equipment or hazardous materials are added

Recognise change and adapt PPE to suit

Develop personal safety responsibility

Develop a personal safety culture, 24/7

THE SHARED RESPONSIBILITY OF PPE COMPLIANCE Human Factors training helps people develop a personal responsability for PPE and safety compliance to help balance those responsabilities of the safety professional and company.

Company Responsibility

Provide Training Provide PPE Develop policies/procedures Remind employees of PPE use Monitor PPE Compliance Develop company safety culture Improve safety at work and at home with human factor training

FL UID ENGINEER S TR A I N I N G G U I DE

Personal Responsability

Actively Participate in Training Choose to ware PPE Follow policies/procedures Build habits around PPE use Self-monitor PPE Compliance Develop personal safety culture Improve safety at work and at home with human factor training

EH S

FACTORS THAT INFLUENCE PPE COMPLIANCE Company Factors

Personal/Human Factors

States (like Rushing, Frustration, Fatigue, Complacency)

Mind not the Task

Choices/Decisions

Recollection (Memory)

Calculations (Risk Assessment)

Rationalisations (of Risk)

Recognition (of change or warning signs)

Anticipation (of error or hazards)

habits/Routines

Motivation

knowledge

Skills

Attitude & Respect

Personal Safety Culture

HOUGHTON I N T E R N AT IO N A L

Rules, Procedures, Policies

PPE Provided (quality, replacement frequency)

Training Provided (on Hazards, PPE Use and Human Factors)

Leadership/Supervisor Support and Commitment

Monitoring/Enforcement

Company Culture

PPE Factors

Style (brand, colour, size, options)

Comfort (fit, weight, thermal properties)

Use (ergonomics, impairing vision or movement, correct type of job/hazard)

Ease of Care (portability, storage, durability)

Replacement Frequency

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

PPE COMPLIANCE IMPROVEMENT COMPARISON

Noncompliance (gap)

Human Factors (fills gap) VERSUS

Traditional PPE Program

Physical PPE

IMPROVING CURRENT PPE PROGRAM \\

Revising your traditional PPE program (new policies, more monitoring, progressive discipline)

Purchasing new, better PPE

PROVIDES INCREMENTAL IMPROVEMENTS

FL UID ENGINEER S TR A I N I N G G U I DE

Physical PPE

ADDING HUMAN FACTORS COMPONENT \\

Adding the missing human factors component of an effective PPE program that gets people to wear their PPE

PROVIDES SIGNIFICANT IMPROVEMENTS

EH S

PPE - SELECTING EYE AND FACE PROTECTION PPE should always comply with the latest UK Legislation & COSHH \\

Safety glasses - Protect from flying material and particulates

Goggles - Protect the eyes, eye sockets, and the facial area immediately surrounding the eyes from a variety of chemical and dust hazardsSafety glasses - Protect from flying material and particulates

Face shield - Protect the entire face from a variety of chemical hazards - Used in addition to safety glasses/goggles to provide adequate protection

Shaded filter lenses (Optical Radiation) - Protect from OR exposures: welding, torch cutting burning, optical

Prescription eyewear - Consider issues with contacts and availability of prescription safety glasses/goggles

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

PPE - SELECTING HEAD PROTECTION PPE should always comply with the latest UK Legislation & COSHH \\

Bump Cap - Low hanging objects â€“Protect from piping, ductwork, machinery, restricted access area etc.

Class C Helmet - Falling objects - Protects when working below other workers, under ladders, conveyor belts, hoists, cranes, derricks, gantries, energized conductors, and heavy machinery etc.

Class G Helmet - Electricity-Protects from 2,200 Volts

Class E Helmet - Electricity-Protects from 20,000 Volts or more

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

PPE - SELECTING HAND PROTECTION TOP 3 HAND INJURIES AMPUTATIONS

BREAKS

LACERATIONS

Hand injuries account for 1/3 of all injuries at

70%

30%

work, 1/3 of chronic injuries, 1/4 of lost working

Due to workers

Due to workers wearing

time and 1/5 of permanent disability.

not wearing gloves

inappropriate gloves

Keep the gloves on!

Protective gloves keep germs and hazardous chemicals off the skin, stop splinters and slivers, resist punctures and cuts from rough or sharp materials and objects, and protect against heat and cold. It is crucial workerâ€™s are wearing gloves that fit correctly since loose-fitting gloves can get caught in machinery.Before using, gloves should always be checked for damage and wear. Workers should use the a glove based on their employerâ€™s hazard assessment.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

PPE should always comply with the latest UK Legislation & COSHH

Metal Mesh, Kevlar, Tough Synthetic Yarn Metal mesh, Kevlar and tough synthetic yarn gloves protect against cuts and punctures are often used by those who work with knives & sharp metals.

Neoprene, Nitrile, Latex, Vinyl Neoprene, nitrile, latex, and vinyl gloves resist petroleum products and chemicals such as oils, acids, caustics, and solvents.

Leather Leather gloves resist sparks, chips, rough objects, and heat.

Cotton Fabric Cotton fabric gloves protect against dirt, slivers, chafing, and abrasion.

Waterproof Waterproof gloves resist wet environments, and are often insulated with foam to protect against cold as well.

Non-Conductive Thinner non-conductive gloves, often referred to as surgical gloves, protect the hands from blood-borne substances, as well as some chemicals and corrosives.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

PPE -SELECTING FOOT PROTECTION PPE should always comply with the latest UK Legislation & COSHH Safety boots may need to provide some or all of the following protection: \\

Steel toe/composite toe & metatarsal - Impact & compression protection

Rubber or vinyl - Chemical protection

Puncture-resistant soles - Protection against sharp objects

Slip-resistant soles - Protection against slippery surfaces

Electricity-resistant material - Protection from electric shock

Insulation - Protect from temperature extremes

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

PPE -SELECTING RESPIRATORY PROTECTION PPE should always comply with the latest UK Legislation & COSHH Respiratory Protection Equipment (RPE) can consist of the following: \\

Face filter - Protects from particulates

Air purifying respirator - Different types of Cartridge available & multiple Cartridge options for risk

Air supplied respirator - Provides clean air or filters air through positive pressure

Self contained breathing apparatus - Not something we would use in normal activity. Requires specialist training

Face Filter Masks only protect from particulates. Air purifying respirators have the following limitations;: \\

Face filter

Effectiveness is chemical-specific

No protection from skin contact hazards

However, they can provide further facial protection combined with full face masks

Service life is limited

Must be face fitted to individual to provide maximum protection

Must be used, maintained & stored correctly

Valves and seals must be working correctly

They can restrict visibility

Increased exertion through lung function

Decreased ability to communicate

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

PPE - SELECTING HEARING PROTECTION PPE should always comply with the latest

Physical pain

130

Gunshot, Metal concert

120

Jet Plane take off

110

Industrial noise

100

Subway train

Lawn Mower

Vacuum cleaner

City traffic

Busy street

Conversation

Refrigerator hum

Ear muffs and earplugs provide about equal

Whisper

protection, ear caps somewhat less

Quiet room

The ear and ear canal varies from person to person

Breathing

Threshold of human hearing

UK Legislation & COSHH Houghton provide and require hearing protection in

Extremely loud

areas with a noise level at or above,

85 DECIBELS A-SCALE (DBA) Very Loud

Hearing Protection \\

Houghton policy requires that we have at least 2 options of hearing protection to choose from

There are three types of hearing protection available â€“ ear muffs, earplugs and ear caps

â€“ensuring the correct fit is a must for making sure the ear plug is actually offering protection \\

Moderate quiet

Faint

Earplugs are made of foam, rubber or plastic and are either one-size-fits-all or in sizes small, medium and large

Some are disposable, some are reusable

They are lightweight, and require no maintenance

They are rolled, inserted into the ear and expand into the ear canal

Easier to wear with additional PPE such as goggles and head protection

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

GHS - WHAT IS GHS? \\

It is the Globally HarmonisedSystem of Classification and Labelling of Chemicals

Labels and SDS`s will be changed

Affected parties:chemical companies, consumers,

It is an approach to defining and classifying hazards for

pesticide applicators and workers, transport workers

chemicals, including pesticides

and emergency responders

GHS - THE PURPOSE OF SAFETY DATA SHEETS \\

Safety data sheets (SDS) are a component of the

Globally Harmonised System (GHS) of Classification and Labelling of Chemicals. \\

than to specific workplaces \\

An SDS gives an employer the ability to develop an

The system standardises & streamlines hazard

active program of worker protection measures and

classification criteria and chemical hazard

training that are specific to the workplace and to

communication elements around the world.

consider the measures that are necessary to protect the environment

Without it, one product requires classification, multiple labels and SDS because various countries’ regulatory systems differed so much.

It’s important to note that SDS relate more to products

Typically, a safety data sheet is used as aninformational sourceabout hazards, including

Safety data sheets also provide critical information for emergency responders, poison centres, transportation companies that move hazardous chemicals, and professionals and consumers who use chemicals.

environmental hazards, and to gather advice on safety precautions.

Example of Houghton Internatonal’s New GHS SDS format Houghton’s new GHS-compliant SDS continues to provide hazard precautionary information about a chemical substance or mixture and will follow a new standardized 16-section format.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

GHS - SAFETY DATA SHEET FORMAT AND CONTENT The safety data sheet contains16 Sections. The format should not vary. \\

1 - Identification – Identify the chemicals on the

and health effects information or indicate if data are

information for the supplier

not available

2 - Hazard(s) identification – Identify the hazards of

evaluate the environmental impact of the chemical if it

associated with them

should be released to the environment

3 - Composition/information on ingredients – Identify

proper disposal practices, recycling, or reclamation of

impurities and stabilizers

the chemical to its container as well as safe handling practices

4 - First-aid measures – Describe initial care to be \\

transporting hazardous chemicals by road, air, rail,

5 - Fire-fighting measures – Provide recommendations

6 - Accidental release measures – Provide

or sea \\

product that is not indicated elsewhere on the SDS

releases including containment and clean-up practices the environment

15 - Regulatory information – Identify the safety, health, and environmental regulations specific for the

recommendations on responses to spills, leaks, or to prevent or minimize exposure to people, places, and

14 - Transport information – Provide guidance on classification information for shipping and

for fighting a fire caused by the chemical

13 - Disposal considerations – Provide guidance on

the ingredient(s) contained in the product including

has been exposed to the chemical

12 - Ecological information – Provide information to

the chemical and the necessary warning information

provided by untrained responders to an individual who

11 - Toxicological information – Provide toxicological

SDS and recommended uses along with contact

16 - Other information – Indicate when the SDS was prepared and when the last revision was made

7 - Handling and storage – Provide guidance on safe handling practices and safe storage conditions

8 - Exposure controls/personal protection – Indicate the exposure limits, engineering controls, and personal protective measures to use to minimise exposures

9 - Physical and chemical properties – Identify physical and chemical properties associated with the substance or mixture

10 - Stability and reactivity – Describe the reactivity hazards of the chemical and chemical stability

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

GLOBALLY HARMONISED SYSTEM for the Classification and Labelling of Chemicals and Chemical Products

1 \\

The legislation will be legally

In Europe, the GHS legislation is

effective for ALL products as of

“CLP regulations – Classification,

1st June 2015.

Labelling and Packaging.”

2 \\

The Global Harmonised System is meant to provide a consistent

5 \\

The most noticeable changes will be to the Product Labels.

framework for the classification, labelling and transport of chemicals and chemical products.

3 \\

Each regulatory region eg; Europe, US, Asia etc, can choose which of the 28 hazard categories they wish to adopt. This is why Safety Data Sheets (SDS) for the same product, but from different regulatory areas, may contain different information.

FL UID ENGINEER S TR A I N I N G G U I DE

PICTOGRAMS - REPLACE PREVIOUS SYMBOLS SIGNAL WORDS - WARNING, DANGER ARE INTRODUCED HAZARD STATEMENTS (H–PHRASES) REPLACE RISK PHRASES PRECAUTIONARY STATEMENTS (P-PHRASES) - REPLACE SAFETY PHRASES

EH S

REMEMBER: IT IS ONLY THE LEGISLATION THAT HAS CHANGED

OLD Hazard Symbols

NEW Hazard Symbols

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

HCS PICTOGRAMS AND HAZARDS HEALTH HAZARD

FLAME

EXCLAMATION MARK

Carcinogen

Flammables

Irritant (Skin and eye)

Mutagenicity

Pyrophorics

Skin Sensitizer

Reproductive Toxicity

Self-Heating

Acute Toxcity (Harmful)

Respiratory Sensitizer

Emits Flammable Gas

Narcotic Effects

Target Organ Toxicity

Self-Reactives

Respiratory Tract Irritant

Aspiration Toxicity

Organic Peroxides

Hazardous to Ozone Layer

HEALTH HAZARD

Gases under pressure

FLAME OVER CIRCLE

Oxidizers

FL UID ENGINEER S TR A I N I N G G U I DE

CORROSION

EXPLODING BOMB

Skin Corrosion/Burns

Explosives

Eye Damage

Self-Reactives

Corrosive to Metals

Organic Peroxides

ENVIRONMENT

Aquatic Toxicity

SKULL AND CROSSBONES

Acute Toxicity (Fatal or Toxic)

EH S

HCS PICTOGRAMS AND HAZARDS The main pictograms due to be seen on Houghton

Silhouette covers substances with Long Term serious

products will be:

harm or Immediate damage to lungs and includes carcinogens, mutagens, repro-toxics and aspiration.

Corrosive pictograms may appear on Soluble Cutting Oils (SCOs) and Cleaners.

Some of our products containing glycols, solvents and low viscosity base oils will carry this pictogram as again,

This is due only to the change in the cumulative

the threshold has changed eg; minimum oil viscosity of

threshold level of substances involved in effects from

7.0 cSt @ 40ºC to 20.5 cSt. The predominant risk being

10% overall content to 5%.

emphasised here is Aspiration. The pictogram will likely

Old `Severe Eye Irritant’ hazards now require a Corrosive pictogram.

be seen on most neat cutting oils (NCOs), some lubricants and some SCOs.

Exclamation mark pictograms cover most previous Low Level Harm and Irritant classifications eg; skin contact, ingestion, irritant to skin & eyes.

P-PHRASES DO NOT TAKE PRECEDENCE OVER CUSTOMERS’ OWN RISK ASSESSMENTS AND COSHH LEGISLATION.

Note: Aspiration occurs when someone ingests the fluid,

Hazard statements (H-phrases) will be similar to previous

vomits and inhales the vomit, subsequently leading to lung

labelling guidance but will be re-worded to produce a set

damage. There is a risk but this is a highly unlikely event.

of `standard’ non-ambivalent phrases.

Remember: In cases of fluid ingestion, DO NOT induce

Precautionary statements (P-phrases) may be triggered

vomiting!

by Hazard statements to provide additional safety and handling advice.

Signal words such as Warning and Danger will appear with pictograms and will always be accompanied by advisory hazard statements to guide the product user.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

SDS - SIGNAL WORDS Signal words indicate the relative level of severity of hazard and are used to alert the reader to a potential hazard on the label. This will always be either:

DA N GER WA RNING If there is no significant \\

This is reserved for the more

severe hazards

This is used on less severe hazards

hazard, a signal word won’t be used

SDS - HAZARD & PRECAUTIONARY STATEMENTS Hazard H -Phrase assigned to a hazard class and category describing nature of hazard and where appropriate, the degree of hazard. Unique alphanumerical code consisting of one letter “H” and 3 numbers.

First number – type of hazard -

First number – type of statement -

“2” physical – “3” health – “4” Environment

“1” general – “2” prevention – “3” response – “4” storage – “5” disposal

Example: H302 Harmful if swallowed Example: P262 Do not get in eyes on skin or on clothing Precautionary P - Phrase assigned describing recommended measures that should be taken to minimise or prevent adverse effects –either from exposure or storage/handling Unique alphanumerical code consisting of one letter “P” and 3 numbers.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

KEY LABEL ELEMENTS: GHS PRECAUTONARY STATEMENT(S)

PRODUCT IDENTIFER

Describes recommended measures to minimize or prevent adverse effects resultingfrom exposure: \\ Prevention \\ Response (including in case of Fire and First Aid) \\ Storage \\ Disposal

Should match the Product Identifier on the Safety Data Sheet

SIGNAL WORDS Either use “Danger” (severe) or “Warnng” (less severe)

PICTOGRAM(S) WITH A RED BORDER

HAZARD STATEMENT(S)

Graphical symbols intended to convey specific hazard information visually

SUPPLIER IDENTIFICATION

The information on the labels will become standardized to increase employee comprehension of the potential hazards and precautions related to the chemical product in each package or container.

HOUGHTON I N T E R N AT IO N A L

SUPPLIER IDENTIFICATION

A phase assigned to a hazard class that describes the nature of the produtc’s hazard

The name, address and telephone number of the manufacturer or supplier

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

SAFE STORAGE, HANDLING AND USE OF CHEMICALS

The HSE HSG 71 (Chemical warehousing) guidance is not

In rare cases, certain stored substances can undergo

compulsory, however if you do follow the guidance you

violent decomposition when engulfed in flame, and an

will normally be doing enough to comply with the law. It is

explosion can result.

aimed at anyone who has responsibility for the storage of dangerous substances, regardless of the size of storage

Dangerous substances should be received into a chemical

facility. It sets out control measures aimed at eliminating

warehouse by a competent person who understands

or reducing risks to people â€“ at work or otherwise â€“ from

all the risks that they pose and can decide on where to

the storage of packaged dangerous goods.

store them and how to segregate them, having regard to their physical and chemical properties, the quantities

It reflects good practice for the design of new storage

concerned and the sizes of the packages.

facilities (and where reasonably practicable, to existing sites) and applies to transit or distribution warehouses,

Dangerous substances arriving on site should be marked

open-air storage compounds, and facilities associated

with the carriage labelling or marking system laid out in

with a chemical production site or end user.

the GHS & ADR Regulations.

In a stores area, fire is generally considered to be the greatest hazard. This is because many people can be exposed to dangers such as radiated heat, harmful smoke and fumes.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

SAFE STORAGE, HANDLING AND USE OF CHEMICALS

Guidance detailed in the SDS & COSHH Information for any

Product will define the safe and correct storage, handling & use of all Hazardous substances; \\

of the largest container) \\

all times

Only use the quantities required or specified

Different products may require different procedures &

Ensure the minimum volumes are handled and transported

All storage must be safe, legal and compliant with

In door warehousing and racking –suitable, accessible, safe and maintained

If transporting a hazardous substance ensure only authorised, sealed and labelled containers are used

National legislation \\

Wear appropriate personal protective equipment for each product being managed

Follow procedures and wear designated PPE at

PPE – do you know what these are for each product? \\

Segregation of incompatible materials -Acids/alkali, Oxidisers/flammables

Be aware of the hazards: Check SDS, COSHH & Labels of all products

Bunding–inside and out (must be able to contain 110%

Any Secondary containers used must also be GHS labelled as per the original product.

Out door bulk tanks -suitable, accessible, safe and maintained

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

COMMON CAUSES OF CHEMICAL INCIDENTS

Lack of awareness of the properties of the dangerous

substances i.e. Hazard classifications and labelling

Poor control of ignition sources, including smoking and smoking materials, hot work, electrical equipment etc

Use of inappropriate containers

Horseplay, vandalism and arson

Use of unlabelled containers

Wearing unsuitable PPE

Use of open ended containers

Poor housekeeping â€“causing Slip, Trip and Fall hazards

Operator error, due to lack of training and other human

Material handling â€“Appropriate equipment to eliminate

factors \\

manual handling

Inappropriate storage conditions with respect to the hazards of the substances

Incompatible materials stored together

Inadequate design, installation or maintenance of buildings and equipment

Exposure to heat from a nearby fire or other heat source

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

SAFE STORAGE, HANDLING AND USE OF CHEMICALS

It is important to have means of controlling spillages

that is at least 110% of the capacity of the single largest

products within Storage areas

container.

Spillage control materials need to be suitable for use

with the product which has leaked \\

Spill containment information is available in the SDS & COSHH Data

The surface of the area needs to be impervious and slightly sloped so that any liquid spilt from containers can flow to a safe contained area

Sufficient Spill medium must always be available and to hand for an immediate response

That bundedarea should be able to contain a volume

and releases while unloading, transferring or decanting

An alternative method to using a bund is to direct spillages of liquid to another area. This could be via a fixed drainage system to a remote sump, interceptor or separator

Unloading should be carried out in a suitable area, away from open drains and ideally within a bundedarea

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

SAFE STORAGE, HANDLING AND USE OF CHEMICALS

You must have a known & safe procedure when dealing

with spillages \\

your site procedures You should wear suitable PPE for the product(defined

Dangerous substances in a fine, dusty state should not be cleared up by dry brushing

Suitable respiratory protection may be needed during clean-up operations

All spillages need to be cleaned up promptly and the material disposed of safely and in accordance with

containment and management

You need to have these readily available for all the substances you manage

COSHH as specific measures may be required for safe

SDS & COSHH Data will detail any specific action to be taken for dealing with spillages

Always consult & be aware of the relevant SDS &

Vacuum cleaners should be used in preference

â€˘In the case of combustible dusts the Vacuum cleaner should not be capable of acting as a source of ignition

in SDS/COSHH) \\

Substances new to the site should not be handled until fully assessed

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

INCIDENTS AND HAZARDS Why should Incidents & Hazards be Reported? \\

It is the first of our EHS Cardinal Rules

We want to have a SAFE workplace. If incidents and hazards are not reported, we cannot correct the

expects that every site Manager will record at least one Hazard ID per month as a minimum requirement \\

This will also be phased into Service Engineer responsibilities for 2019

situations which may affect other employees as well \\

The 2018 Houghton Fluidcare EHS Plan currently

We want to investigate incidents to determine where we can improve our Management Systems to prevent recurrence

We want to share lessons learned from our investigation with other Houghton sites so that they can take preventive actions

INCIDENTS - HAZARD ID`S, NEAR MISSES & ACCIDENTS \\

A Hazard Identification – There are Two Types;

WHEN SOMETHING GOES WRONG….. \\ 1st - We need to take care of the injured person;

– First aid. If a hospital visit is required the person

UNSAFE/SUB-STANDARD CONDITION Is an existing or potential condition which by itself or combined with other conditions has a high

must be escorted \\ 2nd - We need to report it;

- Line manager/supervisor, Accident book and EHS

probability of resulting in an accident or,

AT-RISK BEHAVIOR

\\ 3rd - We need to find out what went wrong and why;

Is an Observable action that increases risk and if

– Investigate, gather evidence, photographs,

not corrected has a high probability of leading to

statements etc.

an accident. \\

department via KMI system / One Call system

4th - We need to prevent a similar incidents;

A Near Miss – Is an event that could have, but did not

– Take preventative measures, use Lessons Learned

result in unintended harm or damage

(Incident sharing) & share globally across Houghton

An Accident – Is an event that results in unintended

EHS to prevent a reoccurence

harm or damage

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

SKIN CARE & THE CONTROL OF DERMATITIS What happens to employees’ hands on the road? \\

dermatological responses to MWF products and other

Mobile workers are at risk without easy access to skin

industrial chemicals

care and hand hygiene. \\

Exposure to a range of contaminants and

There is a wide range of individual susceptibilities and

Dermal exposures to MWF over a period of time may deplete the epidermis (uppermost layer of skin) of

environments can lead to skin disorders.

natural lipids (a process called “defatting”)

Up to 15% of industrial workers suffer from dermatitis.

Approximately 80% of occupational skin disease

barrier against the intrusion of external substances,

occurs as a result of non-immunologic reaction to

the defatting process can cause localised irritation

chemical irritants (irritant contact dermatitis) and 20%

and cracking of the skin which may lead to irritant

to allergic reactions (allergic contact dermatitis)

dermatitis

Although the epidermis is normally a very effective

There are two types of Allergic contact dermatitis

Allergic contact dermatitis: is sensitisationresulting

workers may experience allergic dermatitis which is

in an allergic reaction to something on the skin & can

evident upon contact with fluids

occur a few hours or days after contact \\

There are occasions when conscientious attempts to cleanse exposed skin of fluid deposits can actually

occurs immediately or within minutes of the material

cause or exacerbate dermal irritation \\

For example, workers who engage in excessive hand-

Among workers employed in machining operations

washing/use of harsh soaps may experience dry and

that utilise water-soluble metalworking fluids (MWF),

damaged skin over a period of time

dermatitis is the most prevalent occupational disease. \\

Cases of immunological susceptibility mean some

Contact Urticaria: is an allergic reaction that normally touching the skin

Removal of MWF residues from skin surfaces by

Dermatitis is inflammation (“itis”) of the skin

rubbing with soiled shop cloths that contain dirt/grit

characterised by red itchy rashes that may have well-

and microscopic metal fines may cause fine cuts and

delineated or diffuse patterns.

abrasions of the skin providing ideal skin conditions for infection

Excessive and prolonged dermal exposures to straight oils (no water content) may cause keratoses, acne, and folliculitis.

FL UID ENGINEER S TR A I N I N G G U I DE

However, MWF bacteria on the surface of intact skin are not a known cause of dermatitis

EH S

SKIN CARE & THE CONTROL OF DERMATITIS What potential is there for Dermatitis?

Does anyone have the following symptoms?

Simply answering ‘yes’ to any of the following means you

REDNESS/SWELLING OF HANDS/FINGERS

must take precautions to avoid or address any issues;

CRACKING OF SKIN ON HANDS/FINGERS

Are substances with H-phrases handled?

BLISTERS ON HANDS/FINGERS

Are substances with irritant or corrosive signs

FLAKING/SCALING OF SKIN

handled?

ITCHING OF HANDS/FINGERS

Do workers hands come into frequent contact with

hazardous products? \\

Do workers hands come into frequent and repeated contact with water?

Has anyone suffered from the above symptoms more than once in the last twelve months?

Did anyone then say that their skin got better or the problems went away when they had periods off work?

A medical diagnosis and confirmation of work related dermatitis will require an assessment by a medical professional. However, Safety representatives can provide a useful role in early detection of work related dermatitis and its control.

Common symptoms of dermal disease involving metalworking fluids are summarised as follows:

REDNESS/SWELLING OF HANDS/FINGERS CRACKING OF SKIN ON HANDS/FINGERS BLISTERS ON HANDS/FINGERS FLAKING/SCALING OF SKIN ITCHING OF HANDS/FINGERS SKIN RASH ON LOCALISED AREA OF BODY

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

SKIN CARE & THE CONTROL OF DERMATITIS \\

Control Measures -encourage worker awareness of

the hazards (read Labels, SDS & COSHH; alternative,

Dermatitis. HASWA & COSHH Regulations require that

substitution, engineer, reduce, PPE.

the gloves must be matched to the substance, the work environment, the work and the wearer

Engineering Controls –effective LEV Units, enclosed machining, minimise splashes, negate direct contact

with MC parts and components \\

Standard number (EN 374) \\

& COSHH Data

providing protection against at least 3 chemicals from

Do not use higher than recommended MWF and biocide

a list of 12 (identified by the code letters below the pictogram) for at least 30 minutes.

MWF Maintenance –Correct management of MWF`s. Cleaning of Sumps using system cleaners, removal of

of protection.

Housekeeping –overall cleanliness of workplace, equipment, tools, etc

In either case, no protection can be assumed for any chemical other than the ones mentioned by the

Personal Hygiene –Avoid prolonged wearing of

glove manufacturer.

soiled clothing \\ \\

Similarly, using the gloves for longer than the claimed chemical resistance time may result in loss

Tramp Oil, Fines & Contaminants \\

Gloves conforming to EN 374 can be marked with the ‘chemical flask’ pictogram if they are capable of

concentrations \\

Gloves for use with chemicals will carry a CE mark, a chemical protection sign and the relevant European

PPE –gloves, suitable outer protective clothing, face & eye protection, suitable footwear –as stated in the SDS

An ‘any gloves will do’ approach is a recipe for

Always confirm with the glove manufacturer that their

Skin Care & Products -provide workers with mild hand

products are suitable for the chemicals you use, and

soaps, skin conditioning lotions & barrier creams

duration of wear/use –and be aware that no glove gives

& instigate skin care programmes to promote and

indefinite or 100% protection.

provide good dermal health \\

Health Surveillance –monitor & encourage prompt reporting of early signs of dermatitis

Workers should always seek medical advice/care if dermatitis is suspected

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

SKIN CARE & THE CONTROL OF DERMATITIS

PROTECT

Prework creams help protect

CLEANSE

RESTORE

Appropriate cleansing of

After work reconditioning

the skin against contact with

the hands plays a vital part

creams help maintain the skin in

various workplace contaminants,

in preventing occupational

healthy condition by keeping the

irritants and working conditons

dermatitis. Using the appropriate

skin soft and supple, avoiding

by limiting the contact

cleansers so that hands are

dryness. Good skin condition is

between the two and facillitate

physically clean will remove dirt

an important element in ensuring

subsequent cleansing. This

and irritants while keeping the

good hand hygiene practice.

allows the mildest possible

skin in a healthy condition.

cleansers to be used.

SKIN CARE & THE CONTROL OF DERMATITIS - SUMMARY \\

Know what you are handling

No contact = no contact

Use your Personal Protective

Before you start work with any

dermatitis

Equipment where required

substance make sure that you

For any substance to cause

Your PPE has been selected to

have information about how to

harm, there must first be contact

protect you from the residual

use it safely

between you and that substance.

risk. Make sure it is in good

Ensure that any contact is

condition and used as intended.

Make sure that you follow the safe systems of work in place Safe systems have been

avoided or limited to below the recommended safe limits

Good personal hygiene practices • Avoid contaminated work wear

developed to keep you safe. Do

• Ensure correct hand washing

not take short cuts

and drying • Practice good hand and skin

care routines

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

MANUAL HANDLING The transporting or supporting of a load by hand or bodily force either directly or indirectly. This includes; \\

Lifting

Lowering

Pushing

Pulling

Carrying

Moving

MANUAL HANDLING SHOULD ALWAYS BE KEPT TO A MINIMUM YOU SHOULD ALWAYS USE MECHANICAL AIDS WHENEVER POSSIBLE

MANUAL HANDLING MEDICAL PROBLEMS Traumatic; \\

Strain or Sprain

Slipped/Bulging Disc

Repetitive; \\

Back pain

Neck pain

Shoulder pain

Knee pain

Foot pain

Wrist/Elbow pain

Hernia

Arthritis

Overall Fatigue

FL UID ENGINEER S TR A I N I N G G U I DE

Work Related Upper Limb Disorders - (WRULD) Affects shoulders, arms and wrists - Main Causes: \\

Excessive force

Excessive repetition

Lack of recovery time or rest

Poor static posture

Stress

Individual susceptibility

EH S

MANUAL HANDLING â€“ MANAGEMENT OF YOUR HEALTH

Common causes \\

Poor manual handling techniques

Poor static posture

Sitting or standing in one position for an extended period

Sudden movement

Psychological stress

Vibration during manual handling procedures

Low back pain occurs with the same frequency in

Disorganised workplace will maximise the need for manual handling

Age does not necessarily make a difference, back pain can affect anyone at any age

However, poor handling techniques when you are young can contribute to problems later in life

Being overweight increases the likelihood of back pain

Anyone who has suffered form back pain is three times more likely to suffer from further back related issues

people with sedentary occupations as those in heavy labour

MANUAL HANDLING â€“ THE LAW \\

The Manual Handling Operations Regulations 1992:

These regulations are based on an ergonomic

These are the: \\

Task

Individual Capability

Load

Whereas previous legislation set limits on the weight

Environment

of loads that can be lifted, these regulations require a

Other factors

approach to preventing manual handling injuries. This involves fitting the job to the worker, taking into account anatomy, physiology and psychology.

number of relevant factors to be taken into consideration.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

THE MANUAL HANDLING OPERATIONS REGULATIONS 1992

These regulations are based on an ergonomic approach to preventing manual handling injuries. This involves fitting the job to the worker, taking into account anatomy, physiology and psychology. Whereas previous legislation set limits on the weight of loads that can be lifted, these regulations require a number of relevant factors to be taken into consideration. These are known under the acronym of TILEO

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

MANUAL HANDLING â€“ ASSESSING THE LOAD

TASK

INDIVIDUAL

LOAD

ENVIRONMENT

OTHER FACTOR S

Does the manual handling task involve any of h following: \\

Twisting

Stooping

Bending

Pushing

Pulling

Positioning the load

Sudden movement

Not enough rest or recovery periods

Team handling

Seated work

Is the person: \\

Pregnant

Disabled

Suffering from health problems

Is the load \\

Heavy

Difficult to grip

Sharp

Hot

Cold

Content likely to move

Withn the envirnment is/are there: \\

Space constraints

Uneven Flooring

Slippery flooring

Unstable flooring

Difference in floor levels

Conditions - hot, cold or humid

Is movement or posture hindered by clothing or personal protective equipment?

Is there an absence of the correct/suitable PPE being worn?

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

MANUAL HANDLING – ASSESSING THE LOAD

MANUAL HANDLING – MECHANICAL AIDS

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

DRIVER AWARENESS – INDUCTION & BEST PRACTICE

T HINK AND DRIVE A S E C O N D I S A L L I T TA K E S

Using a Company Vehicle your employer will have

policies and procedures: \\

To make sure that your company vehicle is properly

by using the phone, email or video-conferencing \\

registered, taxed, MOT’d, insured and serviced according to the manufacturer’s recommendations (although you may be responsible for booking the

To check your driving licence, probably at regular

overnight hotel stay must be taken \\

Contact details of the breakdown firm your

A copy of and contact details for your motor insurance

On safe driving, including vehicle checks, journey planning, driver assessment and training, driver

after a long shift \\

emergency services are recommending that people

Driver to complete approved “Safe Driving Awareness

don’t travel unless it is absolutely necessary, consult

Course” \\

your manager and if you cannot contact them, don’t

Your physical and mental health plays a major part in your fitness to drive. You must inform the Company and DVLA about any medical condition that may affect your ability to drive safely

Make sure you understand and follow these policies and

Check weather forecasts and traffic reports before you set off and try to avoid driving in poor conditions. If the

accidents and incidents \\

Plan where you can take a break about every 2 hours, and build in enough time to do so

fitness, speed, alcohol and drugs, mobile phones and other distractions, passenger safety, and reporting

Plan the journey to avoid peak travel times, city centres & busy minor roads wherever possible and especially

policy and your insurer \\

Allow some flexibility to allow for any issues extending the scheduled site service time

organisation uses \\

Allow sufficient time between visits taking into account rest breaks

the person(s) to whom you should report emergencies \\

The schedule must avoid excessive travelling & working hours and where this is not possible an

you are driving In the vehicle, keep copies of the contact details for

Schedule known working week/month to minimise distance and time spent driving

intervals, to ensure that it remains valid for the vehicle

Group sites geographically to minimise travelling time and distance

services) \\

Reduce driving time wherever possible -avoid driving

make the journey \\

Discuss Concerns with Your Manager If you are concerned about your driving hours, journeys or schedules, or if you find yourself driving when too tired, discuss this with your line manager

procedures.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

DRIVER AWARENESS – INDUCTION & BEST PRACTICE You are responsible for ensuring that the vehicle you are driving is safe and legal. Before driving any vehicle, check: \\

Personal Safety \\

It is better not to keep the car doors locked while driving, except if you feel vulnerable in slow moving or

Tyres are undamaged (no cuts or bulges), are at the

stationary traffic. But, always lock the door when you

correct pressure and have enough tread depth. The

are away from the vehicle –even when paying for fuel

legal minimum is 1.6mm, but above 3mm gives much shorter braking distances in the wet \\

There are no signs of vehicle damage

Oil, coolant and windscreen wash levels are correct (check when the engine is cold)

Safe Parking The golden rule is to ensure that others can see you. Bear in mind the time you will be returning to your vehicle –a safe place during daylight may be quite different at night

Leaving the Vehicle Listen and look around before getting out

You know the correct type of fuel for the vehicle

Brakes are working

Lights and indicators are working

Windscreen and windows are not damaged

of it having being tampered with, do not get in – call

Washers and wipers are working

the police.

Mirrors are correctly positioned

If you find a problem report it to your car provider and

you can get in quickly if necessary. \\

Line Manager immediately \\

If you think the vehicle is, or may be, in an unsafe or illegal condition, do not drive it until all necessary repairs have been completed

HOUGHTON I N T E R N AT IO N A L

Approach the vehicle with your keys in your hand so

Check the vehicle as you approach. If there are signs

Road Rage Avoid getting into conflict with another driver, even if they are behaving badly

If you are able to recognise when you become stressed, angry or impatient while driving, you will be better equipped to deal with these emotions. Try to find time occasionally to reflect on your driving and think about how mood or stress has effected your actions

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

Accidents, Breakdowns and Emergencies

Accidents;

Breakdowns;

Stop. It is an offence not to stop, if your vehicle is

involved and damage is caused to another vehicle or

shoulder or emergency refuge on a motorway) and

property or someone is injured

switch on the hazard warning lights

Use hazard warning lights and switch off your engine

Do not move someone who is injured unless they are in immediate danger of further injury from other vehicles

should stand between the vehicle and oncoming traffic \\

circumstances (for example, if carrying any Chemicals) \\

far from the traffic as is practicable \\

and whether children or passengers with mobility

Telephone your nominated contact person to tell them what has happened

Ensure the vehicle is roadworthy before continuing the journey

problems are being carried

Obtain the names and addresses of all independent witnesses (if possible)

Telephone the emergency services, or breakdown firm, giving them accurate details of the vehicleâ€™s location,

If the emergency services are called, stay at the scene until they allow you to leave

Keep passengers together, and children under constant supervision

Give first aid if required and if you are competent to do so

On motorways or other busy roads, passengers should be taken onto the embankment or grass verge and as

If child passengers are present, ensure an adult remains with them

Move passengers out of the nearside of the vehicle and as far away from it and other traffic as possible. No one

Call the emergency services immediately; provide them with information about the situation, any special

If this is not possible, move it as far away from moving traffic as you can

or from fire or explosion \\

Move the vehicle off the carriageway (onto the hard

On a motorway, use the roadside emergency telephone as this will enable the Police to pinpoint your location.

If there is any injury or the names of the people involved are not exchanged, you must report the accident to the Police as soon as possible or in any case within 24 hours

Report the accident to your Line Manager, HR Department & EHS

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

TRANSPORT OF CHEMICALS IN CARS Prior to transporting any chemicals, the car must contain the following items; \\

Personal protective equipment

Chemical gauntlets

Safety goggles

Disposable chemical apron

Respiratory Protection – if required

Chemical spill kit with suitable absorption mats

First aid kit including eye wash bottle

Emergency triangle

Product / chemical safety data sheet for product being transported

Emergency spillage card

THE SERVICE ENGINEER MUST HAVE AN AVAILABLE COPY OF AND FULLY UNDERSTAND THE FOLLOWING DOCUMENT -“TP EHS SOP 034 -THE TRANSPORTING OF CHEMICALS WITHIN CARS FOR COMPANY BUSINESS” – AS THIS DOCUMENT CONTAINS A FULL EMERGENCY SPILL PROCEDURE AND MANDATORY APPROVED PPE/EQUIPMENT LIST OF ITEMS WHICH ALL SERVICE ENGINEERS MUST CARRY AT ALL TIMES

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

TRANSPORT OF CHEMICALS IN CARS \\

The transporting of any chemicals within company or

may leak during transits the container should be placed

alternative delivery methods used

in a sealed clear plastic bag and then placed in the UN storage box

Where the customer requires a regular addition of a \\

The UN storage box should be where possible

a company or private car, the storing on the chemical

secured in the boot of the car to prevent movement in

on the customers site should be discussed with

transport.

the customer to prevent the need to transport the chemical around

Care should be taken when lifting out the container and / or Chemicals from the boot. Avoid stretching by

Where it is not possible due to the nature of the

bringing the container as close as possible towards

task being completed or the urgency of the delivery

you. Have a good grip and use correct lifting technique

then the transporting of a limited quantity of certain dangerous chemicals can be transported based on

the controls stipulated in the corresponding JTRA The storage of all chemicals within cars should be kept

Dip-Slides must be segregated, securely stored and removed ASAP after being taken

compliance with all the aspects of this procedure and

Where there is concern that the transport container

private cars should be AVOIDED where possible and

chemical which currently is being transported within

Samples must be securely stored and taken to the Technical Services centre ASAP

to a minimum and chemicals should be removed at the first opportunity and stored in a safe and secured location \\

All chemicals must be transported, sealed and in their original UN approved packaging and pack size

All chemicals must be transported in a UN approved storage box that will act as secondary containment and provide additional impact protection.

The maximum weight that can be carried within a car is 30Kg â€“this includes the weight of the UN approved carrying crate (3.2Kg)

All the chemicals must be labelled up with their hazard information and associated hazard pictogram

All chemicals must be transported in the boot / truck of the car. Where the car is a hatch back model the boot must be fitted with a parcel shelf which is fully extended

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

TRANSPORT OF CHEMICALS IN CARS Secure Loads -Company Cars \\

rear seats for extra security.

load you carry is legal and safe, even if it was loaded by

If you are not sure whether your vehicle is overloaded, take it to a public weighbridge.

Avoid loose items on the dashboard or rear parcel shelf â€“they will become missiles if you crash

Make sure the vehicle is not overloaded (check the handbook for the maximum weight)

Make sure the rear seat backs are secure and, if not carrying passengers, engage the seat belts across the

As the driver, you are responsible for ensuring that any another person.

Put items in the boot rather than the passenger compartment and distribute the load evenly

It is illegal and dangerous to drive a vehicle that is overloaded or has an insecure load

When driving, remember to account for how the extra weight affects the vehicleâ€™s handling and stopping distances. Check whether tyre pressures should be adjusted when carrying a full load

Remember that a car is not a van, so do not load as much as you can physically fit into it

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

CHEMICAL HANDLING & COSHH \\

Applicable at Fluidcare sites because hazardous

the health hazards. Ensure access to relevant SDS and

regulations to help make dealing with hazardous

COSHH assessments. \\

COSHH Assessment of chemicals: – takes into consideration the hazard of the chemical and the work routine

chemical handling duties. \\

chemicals.

the PPE and other precautions needed to ensure safe

Always wear the appropriate PPE.

handling. It will also include appropriate emergency

Always follow the site safety rules and handling

response measures to be taken Reduce manual handling operation through the use of

requirements pertinent to the product. \\

mechanical aids; \\

Always consult the relevant COSHH assessment for the material before attempting any task involving

The COSHH assessment identifies the health hazards associated with a particular substance and defines

It is your duty to ensure the Safety of yourself and all others who may be impacted whilst carrying out

– specifies hierarchy of control measures – The choices are Elimination, Substitution, LEV or PPE

If transporting a hazardous substance ensure only approved, sealed and labelled containers are used.

– allows identification of safe working practices

Check the product label and ensure you are aware of

chemicals are involved. These are important chemical safe. \\

Use Fork Lift Truck and approved sack trucks, pallet

Always store materials appropriately and ensure incompatible materials are stored separately.

If in any doubt – ASK!!!

trucks and trolleys where applicable. \\

Containers come in 5lt, 20lt, 25lt, 205lt & 1,000lt packs. Use and employ approved lifting techniques & equipment where appropriate.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

COSHH - THE CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 2002 \\

COSHH stands for the ‘Control of Substances Hazardous to Health’ and employers need to either prevent or reduce their workers’ exposure to

A COSHH training course should provide you with: 1.

harm health

substances that are hazardous to their health. \\

The HSE has a free guide ‘Working with substances

2. Knowledge and definitions of exposure limits 3. Skills to understand exposure and to conduct COSHH

hazardous to health’ \\

An understanding of how and which substances can

risk assessments

The guide illustrates how you should assess the risk of your own COSHH substances and what control

4. A greater understanding of practical control

measures you should have in place to reduce employee

measures and safe systems of work

exposure.

COSHH IS APPLICABLE FOR SERVICE ENGINEERS BECAUSE YOU ARE WORKING WITH AND AROUND HAZARDOUS CHEMICALS. THESE ARE IMPORTANT REGULATIONS TO HELP MAKE DEALING WITH HAZARDOUS CHEMICALS SAFER.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

These regulatons require an employer to: \\

Assess the risk to health arising from the Hazardous substance in the workplace

Prevent or adequately control exposure

Ensure that control measures are used and maintained

If necessary, monitor the exposure of employees to

Consider the exposure scenario and duration of the activity

Hazardous substances \\

Apply the COSHH Hierarchy of control measures in order of

Health surveillance \\

Elimination, Substitution, Engineering controls,

Where necessary, carry out appropriate

Ensure that employees are properly informed, trained & supervised

Administrative controls, PPE \\

Decide what precautions are needed

ASSESSMENT \\

Identify Risk

PREVENTION \\

Replace or Substitute

CONTROL \\

Replace or substitute not reasonably practicable

Use Engineered, administrative or PPE controls

MAINTAIN \\

Maintenance, examination, testing & review of control measures

FL UID ENGINEER S TR A I N I N G G U I DE

PROVISION \\

Instruction, training & information

SURVEILLANCE \\

Should be carried out where exposure has potential to cause adverse health effects

EH S

THE SAFE USE OF BIOCIDES & CHEMICAL ADDITIVES \\

Chemical handling training to be presented to all personnel prior to any use of biocides.

Approved risk assessments and standard operating procedures adhered to at all times.

Be fully aware of COSHH data on all materials being handled.

Fully utilise all available site controls to minimise and

Use closed handling or fixed dosing biocide/additive

Practice good housekeeping skills.

Eye wash stations readily available wherever biocide/ additives are used.

Always order the smallest Biocide/ additive pack size

Keep the product in the original container when not in use. Keep container tightly closed.

Keep away from heat.

possible.

Keep away from direct sunlight.

Always use specified PPE appropriate to the materials

Keep away from food and drink.

and task.

Store in a well-ventilated place.

Awareness of all suitable spill kit locations and safe use

Keep securely stored with no access to unauthorised

Utilise manufacturing system LEV systems wherever

of containment materials. \\

systems wherever possible. \\

Awareness of manual handling guidelines.

wherever possible.

limit exposure to biocides/additives. \\

personnel.

Knowledge of the appropriate site/emergency contacts in the event of a spillage.

HAND PROTECTION

EYE PROTECTION

SKIN AND BODY PROTECTION

RESPIRATORY PROTECTION

Chemical resistant

It is a mandatory

No personal respiratory

gloves (Splash

requirement to wear

protective equipment

protection: disposable

tightly fitting goggles

normally required. Use

nitrile rubber gloves.

and a full face visor when

certified respiratory

Prolonged contact:

making any biocide or

protection equipment

Butyl rubber gloves).

hazardous chemical

only when respiratory

DIN/EN374 or DIN/EN388

additions

risks cannot be avoided

Specification

or sufficiently limited by technical means.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

ALWAYS CHECK THE CONTAINER FOR DAMAGE OR LEAKS BEFORE USE.

USE IN WELL-VENTILATED AREAS. AVOID BREATHING ANY VAPOURS FROM NEAT PRODUCT.

THE CONTAINER MUST ALWAYS BE CLEANED OF LEAKS OR DRIPS AFTER USE.

AVOID GETTING BIOCIDES ON THE SKIN BY WEARING IMPERVIOUS CLOTHING WHEREVER POSSIBLE.

HANDLE AND OPEN CONTAINER WITH CARE.

PROCEDURE 1.

Ensure you are wearing the correct PPE dependent

measuring indicators to ensure the dosage volume is

upon the Biocide/additive pack size and graduated

always accurate.

measuring containers being used for dispensing. 2. Ensure that you have the correct dispensing equipment

dependent upon the Biocide/additive pack size and graduated measuring containers being used for dispensing. 3. Biocide/additive additions are calculated based on the

sump size, test results and product usage parameters. 4. 20/25 Litre packs should be fitted with and EHS

approved non- splash pump or as a minimum safety requirement a tap to avoid splashing when decanting. 5. If dispensing directly to a coolant system from a 25

litre drum use a dispensing tap/pump and feed pipe to negate any contact with the biocide. 6. 10 litre packs should be fitted where practicable with a

tap to avoid splashing when decanting. 7. 5 litre packs should be fitted where practicable with a

tap to avoid splashing when decanting. 8. Dispensing containers should have graduated

FL UID ENGINEER S TR A I N I N G G U I DE

9. Dispensing containers should be fitted with lids to avoid

splashing when adding to coolant systems. 10. Inform the operator or cell manager of any remedial

additions required in order for them to relay the information to all relevant personnel on all shifts. 11. Add the product at the required dosage level slowly and

carefully. 12. Add the product directly to the coolant flow so that

the biocide/ additive is quickly and evenly dispersed throughout the coolant system. 13. Do not add biocide/additive to any one area of a coolant

system which is not running. 14. Check for any spillages and dispose of any

contaminated materials as hazardous waste. 15. Carefully clean and store all equipment after use. 16. Observe good hygiene and wash thoroughly especially

after using biocides/additives.

EH S

DRUM HANDLING Corporate EHS issued a Global Mandate to stop the

Our products are packaged in these drums and are

practice of manually moving drums.

distributed for use world-wide.

This mandate is directed to reduce and stop potential

Access to these drums, their use and movement requires

injuries from occurring from the manual “rolling” of drums

specialised equipment.

world-wide. Most drums in use are 205 litres.

DRUMS SHALL NOT BE “ROLLED” MANUALLY – EITHER IN THE VERTICAL NOR HORIZONTAL

SUB-CONTRACTORS Sub-Contractors should provide Houghton PLC with

A Cardinal rules leaflet must be provided and explained

the following documents or information (prior to the

to all Sub-Contractors before the commencement of any

commencement of works) and any amendments during

work onsite.

the course of their work. a. Sub-Contractors Safety Policy b. Employers Liability Insurance certificate c. Work method statements & Risk Assessments d. The names of the Sub-Contractors onsite

Subcontractors using power tools and equipment must provide the necessary certification and registers upon request. Failure to follow or breach of any Customer safety rules, the Houghton Cardinal Rules’ or legal safety obligations will result in immediate removal and exclusion from site.

All sub-contractors and visitors must sign into site and report to the prearranged point of contact before proceeding onto site.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

WORKSTATION SET UP 1.

Adequate lighting - artificial or natural

2. Local task lighting, if required 3. Window coverings to minimise glare and reflections 4. Sufficient space underneath desk to allow postural

12. Software: appropriate for the tasks and user, adapted

to user, providing feedback on performance, no undisclosed monitoring 13. Keyboard: adjustable, detachable, keys legible from

sat position

changes, no obstructions 5. Chair: stable, provides good support, adjustable, allows

easy movement 6. Desk: provides sufficient work surface space, surface

glare/ reflection-free 7. Whole-body facing same direction when using DSE 8. Mouse within easy reach 9. Monitor/screen: stable image, adjustable, glare/

reflection-free 10. Footrest, if required 11. Potential distracting noises minimised

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

BASIC POINTS OF METAL WORKING FLUID’S - DO \\

Manage all fluids properly

Observe manufacturer’s instructions

Be aware of health problems

Check compatibility of fluids

Store drums correctly

Protect fluids from moisture

Check and control concentration

& not only for coolant, but more importantly oils (Hyd’s

Keep a 5 year record of checks

and Lubes)

Top up with premixed emulsion – a little, often, is ideal

Make sure all spray guards and covers are in good order

for optimum condition.

Ensure good coolant flow

Keep the machine clean and debris free

Use LEV systems wherever fitted to prevent misting

Keep the machine sump covered

Ensure filtration systems work

Stop or minimise tramp oil leaks

Report all leaks to the relevant person

Where possible clean all pipe work, machining surfaces

Mix the fluids just before use, try not to store premixed fluid

Know the water hardness

Mix in a clean container.

Always add oil to water with constant agitation

Use PPE - gloves and safety glasses (Ensure clothing is cleaned to prevent infections and skin complaints)

and potential respiratory issues \\

Ensure you have good personal hygiene. (Wash hands after being in contact with coolants and oils. Apply barrier creams to prevent skin complaints)

and guards, before renewing a fluid

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

BASIC POINTS OF METAL WORKING FLUID’S – DO NOT \\

Wait for problems to arise before taking action

Allow tramp oil to accumulate

Mix in dirty containers

Let “in - house” lack of expertise prevent effective fluid

Expose fluids to temperature extremes

Use water from fire hoses

Check the concentration by touch, you will get it wrong

Put clean fluids in dirty machines

Allow mist or sprays to be emitted.

Use a cleaner without checking compatibility with the

Use airlines to blow components or machines clean

Allow unnecessary contact with the hands

Eat or drink around machine tools

Use the machine tool as a refuse unit

Add water to concentrate, it will make an invert

maintenance \\

health and safety, and the general environment will suffer

fluid \\

Allow waste, or rubbish to enter the system (E.g. Blue Roll, rags and food)

Allow overheating to occur, ensure level and flow of coolant are adequate

Allow the fluid to stagnate when not operational

Add biocide without guidance from a specialist, and

Use the fluid past its effective working life - quality,

emulsion which is useless. \\

Dispose of used fluid directly to the drains

never exceed the recommended dose.

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

SUMMARY - WHAT SHOULD YOU DO? \\

Think Safe -Work Safe –Always follow the Houghton &

Site safety rules \\

and report any potentially dangerous situations to your contact or manager promptly - Use the Hazard

Know the site facilities, 1st Aid, emergency procedures

Identification reporting tool on KMI

& safety arrangements \\

Always be aware of potential health and safety hazards

Make sure you have read and fully understand your JTRA (Risk Assessments & Procedures) which will be specific and applicable to you and your sites

Take reasonable care –Always use and store materials, equipment and tools legally and responsibly both onsite and in your vehicle. As soon as you have finished your task ensure you leave any area clean, neat & tidy

Be aware of your surroundings at all times and ensure you treat every site visit as if it is your first onsite – never become complacent

Never try to perform work that you are not qualified to

BUT REMEMBER – NEVER, EVER, DO ANYTHING YOU FEEL IS UNSAFE!

do or have not been properly trained to undertake. This could cause injury to yourself or others

It is your duty to follow & comply with all National & Local Legislation, Customer site rules and all Houghton EHS & Cardinal rules

It is your responsibility to take reasonable care for your own safety and the safety of people working around you

You are absolutely responsible for what you do and for

what you don’t do as you are your own Safety Manager \\

If you are in doubt, just ASK!

Always raise a concern if; \\

You have unsafe access/egress, space, conditions,

unsafe \\

You’ve carefully thought out all the angles

You’ve now done it a hundred times

It now comes naturally to you

You know what you’re doing, its what you’ve been

equipment or PPE \\

You have inadequate instructions or training – ask yourself - ‘Is this my job?’’

You do not have access to safety information (SDS, COSHH assessments, JTRA -Risk Assessments & Standard Operating Procedures)

HOUGHTON I N T E R N AT IO N A L

You are being asked to do something that you feel is

trained to do \\

Nothing could possibly go wrong, right ?

THINK AGAIN!!!!!!!!!!!!

Always be aware

Never be complacent

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

T H I NK S A F E, WO RK S AFE, STAY S AFE!

FL UID ENGINEER S TR A I N I N G G U I DE

EH S

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

A DAY AI NDAY THEI NL ITHE F E OLFI FAE SERV O F AI CSERV E ENG I CIENEER ENG I NEER

A DAY I N THE L I F E OF A SERV I C E ENG I NEER

IN T HE L I F E OF A SERVICE ENGINEER

A DAY F L U I D E N GI N E ER S T R A I N IN G GU I DE FL UID FLUID ENGINEER ENGINEE S TR ARISN ITNRGAIGNUIINDE G G U I DE

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

A DAY IN THE LIFE OF A SERVICE ENGINEER

WHAT IS THE ROLE OF A SERVICE ENGINEER Its to ensure compliance, cost efficiency, productivity and educating the customer on best practice.

REPRESENT THE BRAND

INFORMED

The service engineer is the “eyes

SMART

COMMUNICATIVE

and ears” for Houghton at a customer site.

RESPECTFUL

CUSTOMER PRE-CALL PREPARATION

SITE ARRIVAL – CHECKING IN

Call your customer or Lead contact no later than 24 hrs to

On your arrival to site, make sure you are logged in with

your scheduled visit, if your call is not answered send an

the Gatehouse or sign yourself into the reception book,

e-mail stating your estimated day/time of arrival.

this is a requirement in case of a MEDICAL EMERGENCY. Or FIRE EVACUATION.

Calendar share with your Account Manager but let him

Liaise with your site contact, discuss the previous report

know of your intended site visit and ask him of any

and any site issue

special requests you may need to know about regarding

the site.

Plan in your stock check or stock depletion if this is part of the working contract

FL UID ENGINEER S TR A I N I N G G U I DE

A DAY I N THE L I F E O F A SERV I C E ENG I NEER

JOB ESSENTIALS Workwear & P.P.E \\ Specified Houghton Shirt and Trousers \\ Safety Boots \\ Hard Hat \\ Safety glasses \\ Nitrile Gloves \\ Full Face visor (can be kept on site for Biocide additions) \\ Hi Viz vests & Coat

Tools & Equipment \\ Refractometer \\ PH Strips \\ Pipets

TO DO THE JOB Tools \\ Spanners \\ Allen Keys \\ Thermometer

Paperwork \\ Coshh sheets (On site and in the car) \\ SDS (On site and in the car) \\ S.L.A (Service level agreement .. All Accounts)

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

SERVICE ENGINEER ROADMAP

PRE-CALL PREPARATION \\ Contact customer \\ Speak to Account Mgr.

SITE ARRIVAL

\\ Review previous reports \\ Let contact know your on site \\ Discuss previous visit and any current issues

\\ Agree work schedule

FLUID TESTING \\ Check systems \\ Record results (FluidTrend)

\\ Check stock

CORRECTIVE ACTIONS

\\ Speak to operators \\ Look for opportunities during site walk

\\ Increase / Decrease conc. \\ Remove surface tramp oil

\\ Treat with biocide \\ Check Dosatron

RECORDING AND REPORTING \\ Update machine charts \\ Make Operator aware of issues

\\ Provide feedback on corrective actions \\ Get signed off

LEAVING SITE AND FUTURE ACTIONS \\ Liaise with site contact and outline required actions

\\ Confirm next visit \\ Discuss identified opportunities \\ Contact Account Manager

FL UID ENGINEER S TR A I N I N G G U I DE

A DAY I N THE L I F E O F A SERV I C E ENG I NEER

SELECT YOUR FLUIDSUPPORT SERVICE LEVEL: ESSENTIAL, ENHANCED OR ELITE.

FluidSupport comes in three, extending levels, allowing you to match your needs against budget and requirements. FLUID SUPPO R T

Technican visits per week

ES SENTI AL

ENH ANC ED

EL I T E

Half Day

Full Day

Tailored

Advised

Implemented

n/a

POA tests & checks taken • Concentration & pH checks for all water based products • Bacteria & fungal measurement • Visual tramp oil assessment • Temperature monitored and recorded • Live visual management for all testing • Coolant charts on all machines updated on each visit All corrective actions - additives and product FluidTrend Express software with report issued after each visit FluidTrend software with full customer access Biocide additions made (when required) Stability test for tramp oil conducted monthly POA labels on all machines with QR code for data logger scanner Stock control and management Regular review meetings will be scheduled as required Additional solutions • Equipment • Additional time required • Continuous improvement

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

ORDER OF SERVICE TESTING

CALIBRATION OF REFRACTOMETER

CONCENTRATION TESTING

P/H READING

DIP SLIDE TAKING

INCUBATION OF DIP SLIDES

DIP SLIDE READING

VISUAL MANAGEMENT

TRAMP OIL READING

ODOUR READING

TEMPERATURE READING

Every level of our FluidSupport service is delivered by

Our Service Engineers are on hand to visit, test and

highly trained Service Engineers, allowing customers to

advise on any remedial actions required. Depending on

tap into the Houghton wealth of experience, world-leading

your package, we can implement these actions â€“ able to

products and our consultative approach to support your

provide a bespoke service package to service your exact

operations.

needs and business objectives.

FL UID ENGINEER S TR A I N I N G G U I DE

A DAY I N THE L I F E O F A SERV I C E ENG I NEER

CALIBRATION OF REFRACTOMETER Always refer to your operation refractometer manual for

After this calibration procedure, your instrument is

you modelâ€™s specific calibrating instructions. If you do

calibrated and ok to use.

not have the manual please follow the basic calibrating instructions

This procedure MUST be done at the start of any testing, if testing is to be done for more than one site in a day this procedure must be done again for the second test site.

1. Open the daylight plate and place a few drops of water on the prism. Close the plate so the water spreads entirely across the surface of the prism, if a bubble occurs open and close the daylight plate to release the bubble. 2. Hold the refractometer in the direction of a light source and look into the eyepiece. At this point you should see graduations down the centre (you may have to focus the eyepiece to see the graduations clearly). The upper portion of the field should be blue and the lower portion should be white. 3. . While looking into the eyepiece, turn the calibration of the screw (this can be found on the top or bottom dependant on the model of your refractometer) until the boundary between the upper blue field and the lower white field meet exactly on the 0.0 line

USING A REFRACTOMETER Refractometers are very easy to use, even the non-digital, analog refractometers. Just place a few drops of fluid on the prism as you would if you weâ€™re calibrating the unit, hold the unit up to a light source. Look into the eyepiece and read the scale.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

CALIBRATION SHEET ALL MEASURING EQUIPMENT MUST BE CHECKED AND CALIBRATED PRIOR TO USE

IF EQUIPMENT FAILS DO NOT USE UNTIL IT HAS BEEN RECTIFIED

CONCENTRATION TESTING 1. If possible to do so, always take a sample from the

3. Retract some fluid into your pipet, and place a few

working nozzle of the machine, this will eradicate the

drops of coolant onto the prism of the refractometer

possibility of tramp oil being present and effecting the

ensuring an even film of liquid remains on the prism

concentration reading.

surface when the daylight plate is closed.

2. If taking a sample from the sump of a machine, disperse

4. Hold the refractometer with the prism facing a light

any present tramp oil by circulating your pipet in the

source and look through the eyepiece to obtain a clear

fluid until the fluid becomes clear.

image (adjust the eyepiece to obtain a clear image).

FL UID ENGINEER S TR A I N I N G G U I DE

A DAY I N THE L I F E O F A SERV I C E ENG I NEER

CONCENTRATION READING 1. The upper of view will appear blue and the lower field white. The reading is taken where the blue and white fields meet 2. Once the reading has been taken wipe the prism with a dry cloth

P/H TESTING \\

P/H TESTING â€“ 2 ways to p/h test

Open the daylight plate of the refractometer, while you still have coolant present on the prism take a p/h strip and slide it through the coolant until it changes color, wait approximately 5 seconds before reading the p/h strip, compare the result by comparing the color pattern on the p/h paper against the color scale on the p/h box, record the data on the machine charts.

Retain coolant into your pipet and squirt coolant onto your p/h paper until it changes color, wait 5 seconds as above for reading the p/h result.

DIP SLIDES INSRUCTIONS FOR USE 1. Unscrew the dip slide tongue from the bottle, holding it by the cap to avoid touching the face. 2. Immerse the slide into the fluid, or expose the slide to a spray or running fluid so that both surfaces are covered. 3. Remove the slide from the fluid and allow this to drain for a few seconds. 4. Replace the dip slide into the bottle and tighten the cap

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

INCUBATION FOR DIP SLIDES 1. Turn on incubator at set temperature to desired value. 2. The dip slide should be incubated at 25.0 degrees and in between 24-48 hours for coolant fluids. 3. Used dip slides should be immersed in a suitable disinfectant or bleach overnight and put into contaminated waste DO NOT dispose into normal domestic or recycled waste.

READING DIP SLIDES Control is defined as:

Or take any other measures which are equally effective.

Good control - less than 103 CFU/ml = No further

Keep records of all tests for at least five years.

action is required now. \\

Reasonable control - between 103 and 106 CFU/ml. = You may need to clean the system, or change your biocide regime. Get advice.

Poor control - more than 106 CFU/ml. Act immediately. This normallymeans draining and cleaning.

FL UID ENGINEER S TR A I N I N G G U I DE

A DAY I N THE L I F E O F A SERV I C E ENG I NEER

TRAMP OIL VISUALISATION Tramp Oil = < 2% volume No visible surface oil. Coolant looks typical for the product grade. Tramp oil removal unit is effective. No action required.

Tramp Oil = ~ 2% volume Thin film of brown surface oil. Very patchy overall. Borderline acceptable level. Action can be scheduled to remove surface oil.

Tramp Oil = >2% volume Significant levels of surface oil spread across compartments. Visible coolant looks white and clean. Action should be taken to remove surface oil.

Tramp oil = >2% volume Thick yellow/brown surface oil. Glistening surface suggests a rapid leakage of hydraulic or slideway lube. Action should be taken ASAP to remove surface oil.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

TEMPERATURE, ODOUR AND APPEARANCE \\

The working Temperature of MWFâ€™s is <30 degrees

The odour level ranges from GOOD, FAIR, POOR or FOUL. The Appearance level is from 1-3 (see attachment below for operating levels).

CORRECTIVE ACTIONS 1. Increase/decrease the concentration by adjusting the dosatron where needed. 2. Increase the concentration by adding neat coolant to the machine sump, work out the percentage needed before making any additions. 3. Remove any surface tramp oil by use of site Freddy. 4. Treat system with additive where needed. (Biocide, Machine cleaner)

FL UID ENGINEER S TR A I N I N G G U I DE

A DAY I N THE L I F E O F A SERV I C E ENG I NEER

SITE VISUALISATION \\

Notice Board

Machine Charts

Product Data Labels

POA Labels

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

BIOCIDE ADDITIONS AND MEASURES Care should be taken to ensure that the amount of biocide

Underdosing of biocides can be worse than not treating

added to a system is in line with the recommended dosage

the system. The addition itself will not have the desired

of the biocide supplier. The true system volume must be

effect and is simply a costly exercise.

known to allow accurate calculation of dosage.

It may also lead to resistant strains of bacteria that are

Repeat doses of biocide need to be monitored to avoid

more tolerant and require a higher dose of biocide to

the build-up of biocides in a fluid.

control.

The addition of any biocide should be done by trained staff after consultation with the fluid supplier.

Always add the product directly to the coolant flow so

Do not add Biocide/Additive to any one area of a coolant

that the biocide/additive is quickly and evenly dispersed

system which is not running.

throughout the coolant system, if the machine is stood when an addition is needed to be made, ask a member of staff to switch the machine on and run the coolant

For a machine with a 1000ltr sump @0.15 = 1.5 ltrs of biocide to be added to the system.

thoroughly until a good mix is made.

CERTIFICATIONS AND ACCREDITATIONS \\

Environmental & Energy Policy Statement

ISO9001 (Quality Management System)

Houghton H&S Statement

OHS18001 (Occupational H&S Safety

Houghton Quality Policy

ISO 14001 (Environmental Management System)

ISO 50001 (Energy Management System)

FL UID ENGINEER S TR A I N I N G G U I DE

Management System) \\

Insurance Document (Personal and Car)

A DAY I N THE L I F E O F A SERV I C E ENG I NEER

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

FL U I D TREND

TRAINING GUIDE

FLUIDTREND F L U I D E N GI N E ER S

FL UID FLUID ENGINEER ENGINEE S TR ARISN ITNRGAIGNUIINDE G G U I DE

F L U I D TR F L END U I D TREN D

FLUIDTREND: THE BEATING HEART OF YOUR MACHINE MAINTENANCE PROGRAMME #CNC-TLC

This tailored and bespoke software program was developed by Houghton to support our FluidcareÂŽ and your Metalworking Fluid operations. The system is auditable and allows users to identify both performance and cost trends for any given machine or system immediately. Designed for optimum coolant and lubrication

FluidTrend is an intuitive and user-friendly customer

management, all analytical results from each machine

portal allowing machine reports and trends to be

test are automatically recorded and promptly displayed

generated quickly and easily. FluidTrend allows you to

on FluidTrend, displaying the condition of the coolant

make informed decisions in regard to your production

at any time, enabling trends to be displayed and reports

activities with complete confidence.

generated instantly on an easy-to-use interface. \\

Effectively manage and control your metalworking

FluidTrend can easily assist with lubrication duties, able

fluids: increase fluid lifetime and reduce waste

to collate data generated during oil top-ups, providing

disposal, helping you reduce your environmental

insightful reports by application point, such as top

impact

leakers, top users, as well as cost analysis and usage trends. FluidTrend management reports aid compliance

Increase productivity, reduce operating costs:

with Environmental, Health & Safety (EHS) guidance on

improve tool quality and life, reduce machine

the control and disposal of metalworking fluids.

downtime and fluid usage

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

FLUIDTREND DASHBOARD & NAVIGATION Designed for optimum coolant and lubrication

FluidTrend can easily assist with lubrication duties, able

management, all analytical results from each machine

to collate data generated during oil top-ups, providing

test are automatically recorded and promptly displayed

insightful reports by application point, such as top

on FluidTrend, displaying the condition of the coolant

leakers, top users, as well as cost analysis and usage

at any time, enabling trends to be displayed and reports

trends. FluidTrend management reports aid compliance

generated instantly on an easy-to-use interface.

with Environmental, Health & Safety (EHS) guidance on the control and disposal of metalworking fluids.

Left Hand Navigation

Your Personalised Reports. These are reports that you have added to the dashboard. Remove using the red minus in the corner of each panel.

FL UID ENGINEER S TR A I N I N G G U I DE

Watch the video tutorial or get help click for an overview describing the functions of each page.

Quick Links navigate to different areas of the portal.

Add New Report to Dashboard - see next page for more information.

Screen mode automatically slides through reports on your dashboard in full screen, which can be displayed on a factory screen.

Notifications that confirm dashboard action.

F L U I D TR END

ADD REPORT TO DASHBOARD With the add report to dashboard panel, you can add personalised reports that are accessible at your fingertips, as soon as you login. Remove reports from your dashboard by clicking the red minus button.

Configure exactly what reports you’d like to have on your dashboard from the dropdowns on the popup, and then click the “Add New Dashboard Report” button.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

MACHINES The machines section of FluidTrend gives you an overview of the status of all of the machines within your factory. The machine cards display a range of quick information, including days since last cleanout, bacteria, concentration and pH status.

The location dropdown filter allows

Change the view to your preference

you to pinpoint machines in

â€“ card or list view

specific areas

Using a simple traffic light status system, the colour-coded cards allow you to quickly scan All of your machines are displayed

across your range of machines â€“ with the ability to

within their sites and locations

click into that machine and investigate deeper into any issues.

FL UID ENGINEER S TR A I N I N G G U I DE

F L U I D TR END

MACHINE STATUS The machine status page displays historical data for any given machine, alongside its Point of Applications (POAs).

The data shown below is determined by the date filters at the top of the page.

Different POA’s data is displayed in different tabs. See next page for more information.

HOUGHTON I N T E R N AT IO N A L

The traffic light system is used here again to determine machine performance.

A profile overview area gives information on the machines site, location, capacity, product it’s using, current statuses, days since last cleanout and tests.

If you wish to quickly generate a PDF report with all information on the machine, click the generate report button in the top right of the screen

A table summary gives information on the history of each of the core tests

More detailed information is then shown for each test completed on the machine which adheres to health and safety regulations – including results for bacteria, concentration, fungi/ yeast, pH and tramp oil.

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

Using the tabs at the top, you can select other POA’s for the machine, with relevant data being displayed. POAs such as ‘Hydraulic’ show you cost and usage data trends.

Select alternate POAs to view their data. Alternate POAs (such as ‘Hydraulic’) may display different information regarding cost & usage.

FL UID ENGINEER S TR A I N I N G G U I DE

Relevant reports are displayed below. As this POA is a ‘Hydraulic’, cost & usage data is displayed.

F L U I D TR END

REPORTS This is the home to all reports. Like the machine status page, the date filter determines what data is shown below within the test reports. Standard reports include:

\\ Top Leakers – machines with the highest amount of volume leaked

\\ Top Users – machines with the highest amount of volume added

\\ Machine status – compare the latest results of all machines across locations

Below are Test, Cost and Usage Reports. Within the Test Reports, data is displayed that gives a detailed overview to your factory’s performance. For Cost and Usage Reports, specify products, machines and locations in which to compare. It is as easy as clicking the ‘start report’ button, entering the desired information to be displayed, and generating! This will create a PDF in your browser, which you can download and print.

\\ Machine History – a specific machines historic results.

Standard reports (as detailed above)

Test Reports

Cost & Usage Reports

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

After youâ€™ve generated a report using the popup and filters, your report will be generated in a new window. From here, you can download the PDF for digital use, or print.

FL UID ENGINEER S TR A I N I N G G U I DE

F L U I D TR END

FLUIDTREND SCHEMATIC

Add Report to Dashboard

Dashboard

Machines

Reports

Screen Mode

List View

Standard Reports

Sites / Locations

Test Reports

Machine Status

Cost & Usage Reports

Generate PDF Report

POAs

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

FLUI DTR E N D.SO L U TI O N S

FL UID ENGINEER S TR A I N I N G G U I DE

F L U I D TR END

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

TRAINING GUIDE

EQUI PEMENT

EQ U IP MEN T

F L U I D E N GI N E ER S

FL UID FLUID ENGINEER ENGINEE S TR ARISN ITNRGAIGNUIINDE G G U I DE

EQ U I PMENT EQ U I PMEN T

CONTENTS

STORAGE

MIXING & DISTRIBUTION

TREATMENT & MAINTENANCE

6 DRUM OR IBC STORAGE

16 VENTURI MIXER

28 FLUIDWORKER

8 POLYETHELENE SPILL PALLETS

18 DOSATRON

30 FREDDY VACUUMS

10 STEEL SPILL PALLETS

20 FLUIDMIX

34 COALESCER

12 BULK STORAGE TANKS

22 DISTRIBUTION PIPEWORK

36 SKIMMER

24 FLUIDCONTROL

37 C-THRU SEPARATOR 38 FILTRATION 40 SEPERATION

ENVIRONMENT, HEALTH & SAFETY

COST RECOVERY

WASTE TREATMENT

44 MIST EXTRACTION

54 BRIQUETTING

66 VACUUM EVAPORATORS

46 LEV TESTING

58 FINE PARTICLE SEPERATION

68 EVAPORATORS

48 AIR MONITORING

60 COOLANT MANAGEMENT SYSTEMS

50 SPILL MANAGEMENT

EQUIPMENT SO LUT I O N S

????

HOUGHTON PARTNERS WITH EQUIPMENT MANUFACTURERS TO SUPPORT CUSTOMER GOALS IN REDUCING FLUID USAGE, MINIMISING COSTS AND GAINING OPERATIONAL EFFICIENCIES. FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

Houghton supply a complete range of self bunded tanks and storage containers for external and internal storage applications that comply to the current regulations.

The storage of fluids is governed by slightly differing regulations highlighted below: \\

The Control of Pollution (Oil Storage) (England) Regulations 2001(OSR England)

The Water Environment (Oil Storage) (Scotland) Regulations 2006

The Control of Pollution (Oil Storage) Regulations (Northern Ireland) 2010

Additionally in England the EA can enforce the requirement to provide secondary containment for oil storage facilities within buildings using powers under

 DRUM OR IBC STORAGE  POLYETHELENE SPILL PALLETS  STEEL SPILL PALLETS  BULK STORAGE TANKS

EQUIPMENT SO LUT I O N S

STORAGE

Section 161A Water Resources Act 1991

THE REGULATIONS STATE: The container must be situated within a secondary containment system which satisfies the following requirements: “It must have a capacity of not less than 110% of the container’s storage capacity or, if there was more than one container within the system, of not less than 110% of the largest container’s storage capacity, or 25% of the aggregate storage capacity, whichever is greater.” Houghton supply a complete range of self bunded tanks and storage containers for external and internal storage applications that comply to the current regulations.

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

DRUM OR IBC STORAGE

STO R AGE

BULK STOR AGE CO NTAI NE R S. DRUM OR IBC BUNDE D STO R E 48 DR UMS O R 1 2 I B C.

Description The base of this bunded store is

strength) while the roof is pressed with

manufactured from 3mm mild steel sheet

suitable bracing). The store is welded around

with RHS cross members and pressed

the perimeter (sump fully seam welded) and

ribs. The corner posts, shelf frames

fitted with crane lifting points (maximum 2000

and main rails are all made from rolled

kilos per lift point), while the triple steel sliding

hollow section. The back, sides and door

doors on each side are mounted on an easy

are pressed from 2mm mild steel sheet

glide track and the unit is shot blasted before

(corrugated as required for additional

being painted.

Features & Benefits \\

Fully enclosed self bunded

No need for civil bund

All sumps compliant with

No requirement to maintain integrity civil bund via bund inspections

UK regulations \\

25, 205 and 1000 litre container storage

Secure storage of fluids

Large range of standard sizes available

EQUIPMENT SO LUT I O N S

Bespoke variants available

Fire rated options available

Conform to environmental legislation

Controlled access to fluids

Units available to suit different amounts of containers

Suitable for indoor and outdoor location

????

DRUM OR IBC STORAGE

STO R AGE

Technical Specification SP E CI F I CAT I ON Size

8840 mm L x 1500 mm W x 3295 mm H at highest point

No. of containers

48 x 205 ltr or 12 x 1000 ltr

Sump capacity

3300 ltr

Shelf space

1350 mm

Colour

Green RAL 6029

Tare weight

2800 kg

Note The “floor” area above the sump in the drum store areas are covered with galvanised steel channel sections so that loose drums or pallets can be stored directly on to them, while the upper shelf is an open, box section construction designed to support pallets. Grid mesh shelving is available for the upper shelf as a chargeable option for those who wish to have it fitted with a full “floor”. Please contact us for further information.

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

POLYETHYLENE SPILL PALLETS

STO R AGE

IND OOR BUNDED STO R AGE . POLYETHYLENE SPI L L PAL L E TS.

Description For the indoor storage of barrels and 1000

single unit. All units are manufactured from

litre containers, IBC, various spill pallets

polyethylene to form a robust plastic drum

are available, suitable to store from one

spill pallet and fully complies with all the UK

to eight barrels and one to two IBC on a

regulations relating to sump capacities.

TWO BARREL SPILL PALLET

TWO IBC SPILL PALLET

This robust plastic drum spill pallet is

Allows you to store 2 x 1000ltr IBCâ€™s side

suitable for a use with a wide range of

by side on the plastic mesh deck. The

chemicals. Manufactured from medium

large capacity sump meets Environment

density polyethylene it has a removable

Agency guideline PPG26 and the 110%

mesh deck.

regulations covered in all the UK Oil Storage Regulations.

EQUIPMENT SO LUT I O N S

????

POLYETHYLENE SPILL PALLETS

STO R AGE

Features & Benefits \\

Rotationally moulded

No seams to leak

All sumps compliant with UK

Conform to environmental legislation.

Flexible bunding solution

Units available to suit different

regulations. \\

Spill pallets available for 25, 205 and

1000 litre container

Easily re-sited

Covered options available

Good chemical compatibility

amounts of containers \\

Covered options suitable for outdoor locations

Wide variety of fluids can be stored

Technical Specification SPE CI F I CAT I ON F OR TWO BARRE L SPILL PALLE T Size

1220 mm L x 820 mm W x 330 mm H

No. of containers

2 x 205 ltr

Sump capacity

240 ltr

Colour

Blue

Tare weight

23 kg

SPE CI F I CAT I ON F OR TWO IBC SPILL PALLE T Size

2560 mm L x 1350 mm W x 510 mm H

No. of containers

2 x 1000 ltr

Sump capacity

1140 ltr

Colour

Blue

Tare weight

2500 kg

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

STEEL SPILL PALLETS

STO R AGE

IND OOR BUNDED STO R AGE . STEEL SPILL PA L L E TS.

Description Our range of indoor bunded storage units provide an immediate solution to the problems associated with safely storing small or large quantities of liquids in drums and IBC’s.

FOUR BARREL BUND Manufactured from galvanised steel this

TWELVE DRUM INDOOR BUNDED STORE

spill pallet has a fully seam welded sump

Designed to hold twelve 205ltr drums

that is fully compliant with all the UK

horizontally this bunded store is manufactured

regulations relating to sump capacities

from 3mm steel plate and has RHS cross

and a removable galvanised steel grid

members, pressed ribs and a heavy duty RHS

mesh deck is fitted as standard as are

end frame with 2mm corrugated panels.

the 150mm wide fork hoops, which are used for moving the pallet and keep the

The front of the store is open for ease of

underside of the sump off the ground.

access and safety ‘stop rails’ at the back prevent drums from being pushed through. With galvanised support channels and a fully seam welded sump the store is fitted with plinths to eliminate contact with the ground and is shot blasted before being painted.

EQUIPMENT SO LUT I O N S

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STEEL SPILL PALLETS

STO R AGE

Features & Benefits \\

Constructed from steel plate fully seam welded

All sumps compliant with UK regulations

Fork hoops

F lexible bunding solutions

Units available to suit different amounts of

1000 litre containers Removable mesh deck

Conforms to environmental legislation

containers

Spill pallets for 205 and

Bund easily cleaned allowing bund capacity to be maintained

Easily re-sited

Technical Specification SPE CI F I CAT I ON F OR TWO BARRE L SPILL PALLE T Size

1220 mm L x 1220 mm W x 406 mm H (including fork hoops)

No. of containers

4 x 205 ltr

Sump capacity

440 ltr

Tare weight

58 kg

SPE CI F I CAT I ON F OR TWO IBC SPILL PALLE T Size

L3000 x W1500 x H2875 mm at the highest point on the unit

No. of containers

Twelve 205 ltr drums - horizontal

Sump capacity

1125 ltr

Colour

Green RAL 6029

Tare weight

700 kg

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

B U L K STO R AG E TA N KS

STO R AGE

BULK STOR AGE TA NKS. 40,000 LITRES TO 1,0 0 0 L I TR E S.

Description All the tanks Houghton supply comply to

the tanks are legal and follow Environment

all current legislation the steel oil storage

Agency (EA) and Scottish Environmental

tanks are certified to OFTEC’s OFS T200.

Protection Agency (SEPA) ‘Pollution

This is the only environmental standard that guarantees compliance with

Prevention Guidelines’ (PPG2) for compliance with all oil storage regulations.

the Control of Pollution Regulations

To safely store any lubricating oils, hydraulic

in England and Northern Ireland and

oils etc, and to ensure compliance with oil

the Water Environment Regulations

storage regulations we use OFS T200 Totally

in Scotland. OFS T200 ensures that

Enclosed Bunded Unit (TEBU).

Optional

EQUIPMENT SO LUT I O N S

Overfill alarm

Bund alarm

Pumps (electric/pneumatic)

Off-set fill point

Level sensors and switches

Dipstick

Hydrostatic gauges

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STEEL SPILL PALLETS

STO R AGE

Features & Benefits \\

Self bunded

Certified to OFTEC’s OFS T200.

Standard and bespoke sizes available

Comprehensive standard

specification \\

Optional accessories available

No need for civil bund

No requirement to maintain integrity of civil bund via bund inspections

Conform to environmental legislation

Economies of scale with standard sizes

Can be manufactured to fit foot print available

Tank specification can be tailored to meet all requirements

Technical Specification SPE CI F I CAT I ON Nominal capacity

10,000 Litres

Dimensions

4632 mm long x 2000 mm wide x 1250 mm tank height (overall height including base bearers and top fittings 1500 mm approx.)

Dry weight

1650 kgs approx.

Standard features

2” BSP fill with nipple and cap Pump plate with 2” BSP socket 600mm diameter manhole (over 3500 litres) 2” BSP top drain connection with plug 2” BSP spare connection with plug Bund inspection port Vent/overflow into bund Float gauge and float guard Sump box Base bearers Lifting lugs

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

Houghton can provide a number of options based on usage and flow required, ranging from barrel top mixers to mechanical mixer stations with self monitoring capability, along with the option to supply and install a dedicated coolant distribution pipework system linked to a coolant mixer. Houghtons dedicated team of fully trained engineers can design, project manage and install bespoke coolant distribution installations to the highest of standards. Our installations include quality pipework, drop points and hose reels.

 VENTURI MIXER  DOSATRON  FLUIDMIX  DISTRIBUTION PIPEWORK  FLUIDCONTROL

EQUIPMENT SO LUT I O N S

MIXING & DISTRIBUTION

Accurate and consistent coolant mixing is critical to ensure the performance and longevity of metalworking fluid, concentration control is of paramount importance and care should always be taken to maintain the recommended coolant dilution rate, so to optimise the fluid performance and not to waste fluid or incur operational issues.

Clear benefits of introducing a bespoke coolant and mixing distribution system to your manufacturing facility include optimising and managing coolant performance within the specified parameters, no manual handling of neat or mixed coolant, a cleaner working environment reducing the possibility of drips and spills and also coolant and waste cost reductions associated with greater management of the product.

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

VENTURI MIXER

MIX ING & DISTRIBU TIO N

COOL ANT MIXING & DI STR I B UTI O N. VENTURI MIXER .

Description Venturi pumps are commonly used for

subsequent problems of corrosive machine

coolant mixers, the moving water across

maintenance, fluid rancidity and the final

the orifice creates a vacuum, drawing

expense of fluid disposal.

coolant into the water stream. The combination of the two laminar flows

The Venturi mixer is extremely simple to

creates a turbulent zone thoroughly

install and operate and is driven by the water

mixing the two fluids. Since there are

pressure alone so no additional equipment or

no moving parts, the pump has a high

power is required. Just switch on the water

degree of reliability. The concentration is

supply when re-filling your coolant tank and

easily altered by the needle valve which

the accurately mixed and blended liquid is

allows for great precision in setting the

dispensed.

proportion of coolant mixed with water. Developed to meet the strongest demands

EQUIPMENT SO LUT I O N S

These mixers eliminate the traditional

from waterworks all over the world for

manual fluid mixing methods which often

category 3 fluids and ISO EN1717. Build-In

result in poor fluid concentration with

double check valve and vacuum breaker.

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VENTURI MIXER

MIX ING & DISTRIBU TIO N

Features & Benefits \\

Simple to operate

Operated via water pressure on

Easy installation fits into large

Durable and reliable

Savings on cutting fluids usage compared

barrel bung \\

Ensures a correct and uniform blending of metal cutting fluids

Rapid and easy adjustment of additive mix

to manual mixing

Built in double check valve and vacuum breaker

Reduces labour cost compared to manual blending

Consistent coolant mix

Approved to water authority regulation

Technical Specification SPE CI F I CAT I ON The lower threaded adapter fits all standard drums. Unique nozzle/jet system that prevents blocking. Flow up to 900/2000 litre/hour. Mixing ratio from 0 to approx. 16% Hook provided on discharge hose

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

D O S AT R O N

MIX ING & DISTRIBU TIO N

DOSATRON D3R E 10 . WATER- POW ERE D PR O PO R TI O NAL DO SI NG PUMP.

Description The Dosatron water powered dosing

the water, and the water pressure forces

pump is a simple and ingenious system

the solution downstream. Once adjusted,

that has demonstrated its worth for many

the dispenser requires no action or external

decades in over a hundred countries.

control.

Installed directly into a suitable the

The dose of concentrate will be directly

water supply line, the Dosatron operates

proportional to the volume of water entering

without electricity; it uses the flow of

the Dosatron, regardless of variations in flow

water as the power source. The water

and pressure which may occur in the main line.

activates the Dosatron, which takes up

EQUIPMENT SO LUT I O N S

the required percentage of concentrate

The high dosing precision eliminates the

and injects it into the water. Inside the

risk of over and under dosing maintaining a

Dosatron, the concentrate is mixed with

consistent product dilution.

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D O S AT R O N

MIX ING & DISTRIBU TIO N

Features & Benefits \\

Simple to operate

Durable and reliable

Not effected by water pressure and

Savings on cutting fluids usage compared to manual mixing

flow variations \\

Ensures a correct and uniform

manual blending.

blending of metal cutting fluids \\

Rapid and easy adjustment of

High level of concentration accuracy and repeatability of results

additive mix \\

Reduces labour cost compared to

Operated via water pressure only

Mixed solution on demand

Technical Specification SPE CI F I CAT I ON F OR TWO BARRE L SPILL PALLE T Injection range

Injection rate 1 -10 %

Water flow range

10 l/h - 3 m3/h

Operating water

Operating water pressure; 0.5 â€“ 6 bar

pressure

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

FLUIDMIX

MIX ING & DISTRIBU TIO N

COOL ANT MIXING A ND SUPPLY UNI T

Description FluidMix is a stand-alone coolant mixing

machine tool sumps throughout an entire

station. Connected to a distribution

workshop on demand or locally via a trigger-

pipework, the system is capable to

nozzle. The operator can choose between four

automatically mix and distribute water

pre-set concentrations which are passcode

soluble coolant with a pre-set, accurate

protected.

and consistent concentration to any

Features & Benefits \\

Accurate top-up mix every time for all

with up to 4 pre-set concentrations

machine tools \\

between a range of 0.5% to 10%,

Tight and continued stable emulsion

protected by a passcode

concentration using innovative mixing technology reducing

off with warning beacon and display

to 25%

notification that safeguards the equipment

Fast delivery of coolant up to 90 \\

EQUIPMENT SO LUT I O N S

Eliminates operational issues and

system or locally via a trigger-nozzle

hazards e.g. constantly varying

/ hose reel

concentrations in sumps, manual

Conforms with EU/UK Water Authority Regulations

design

High flexibility with either automated coolant distribution through pipework

Optimises space on the shopfloor with a small footprint and portable

standard mixing devices

Low concentrate / low water shut-

concentrate & water consumption up

litres per minute –7 times faster than

Comes as “plug and play” system

handling and slip hazards associated with manual mixing, storing and transporting of mixed coolants

No stored mixed coolant necessary

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FLUIDMIX

MIX ING & DISTRIBU TIO N

Recommendation for Use

Application

The product is compatible with

FluidMix is the ideal solution for

Houghton’s soluble fluid portfolio.

customers with a larger number of metal

Please configure the FluidMix to the

working machines with single sumps or

recommended mixing concentration for

central systems to automate the top-

the fluid that you are using. For more

up. The innovative mixing-technology

information, please contact your local

using three pumps ensures a very

Houghton representative.

tight and continued stable emulsion

Locate the FluidMix in a position which is convenient to the layout of your machine shop considering main water and electrical supply. In an ideal situation,

concentration in the machine tool sumps and eliminates the risk of manually mixing and handling coolant in workshops!

the system should be positioned in the centre of the workshop to keep the pipework as short as possible.

Technical Specification SP E CI F I CAT I ON

DE SCRIPTIO N

Width/Depth/Height

1000/1050/1700 mm

Weight

450 kg (empty)

Water Tank Capacity

800 ltr

Electrical

230 Vac ± 10%, 16 A min.

Water Mains Supply

¾” BSP (female) compression fitting, minimum water flow 90 litres/min.

Coolant Conentrate Lance

Suitable for 200 ltr. barrels or 1,000 ltr. IBC-containers

Mixed Coolant Factory

¾” BSP (female) compression fitting, up to 90 litres/min.

Supply

(for factory supply pipework recommendations please see user manual)

Mixed Coolant Trigger-

Dispense mixed coolant locally with up to 90 litres/min.

Nozzle

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

DISTRIBUTION PIPEWORK

MIX ING & DISTRIBU TIO N

COOL ANT MIXING & DI STR I B UTI O N

Description To maximise the benefits of a mixer

or manually controlled, or alternatively a

station the connection to a coolant

retractable hose reel strategically positioned

pipework distribution is the next logical

can serve a cell of machines.

step, treating coolant as being another service for the machine tools. utilising

Treating the coolant as another service, that

a pressurised system means coolant is

needs to be delivered to the machine tool via

only mixed on demand when required

pipe work distribution, removes the issue of

with no reservoir of mixed coolant

having multiple coolant barrels and individual

required. Mixed coolant typically set at

mixing systems on the shop floor, along with

top up concentration, lower than the

the associated bunding for environmental

initial fill concentration to counter act the

protection. Additionally the slip risk of spilled

effect of evaporation, during the cutting

coolant, by manually moving of mixed coolant

process, can be delivered directly to the

in containers, is eliminated.

machine tool sump or if required a cell of machines.

houghton has the ability to design and install small local distribution systems to large

Delivery of the mixed coolant to the

factory wide installations.

machine tool sump can be automated

EQUIPMENT SO LUT I O N S

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DISTRIBUTION PIPEWORK

MIX ING & DISTRIBU TIO N

Features & Benefits \\

Mixed coolant fed to point of use

Coolant delivered mixed on demand

Built in flexibility into pipe work

Ability to service complete shop floor

Individual outlets can be metered

Savings in labour and lost time

Reduction in environmental spillage issues

Shop floor cleared of multiple barrels

Machine moves easily accommodated

Volume / cost of coolant can be determined by outlet

Technical Specification SPE CI F I CAT I ON Pipe work rigid plastic Large bore high level pipework Individual delivery legs smaller bore Incorporate high and low level isolation valves Fill methods, Automated level control; Individual, flex and trigger nozzle, retractable hose reels

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

FLUIDCONTROL

MIX ING & DISTRIBU TIO N

F UL LY AUTOM ATE D CO NDI TI O N MO NI TO R I NG, ANALYTICS AND AUTO - TO P- UP SYSTE M. Description FluidControl automatically measures, analyses and monitors the watersoluble cooling lubricants. The system continuously records all relevant parameters throughout the process and makes them accessible in the FluidControl-Cloud or FluidTrend software from anywhere at anytime. Thanks to a sophisticated cleaning process, the sensors will stay clean for a long time, making FluidControl extremely low-maintenance. Using real-time measurement analysis results,

of coolant level in machine sumps as well as

FluidControl initiates quality assurance

coolant concentration, pH, conductivity and

methods including automatic control

temperature.

Features & Benefits \\

Monitoring, analysing and

screen and isolator switch

visualisation of real time data â€“ from anywhere at any time \\

Identify fluid irregularities in advance with a mouse-click

Close control minimises cost of fluid maintenance and usage

Increase tooling life-time

Increase quality of finished goods

Can be installed on single sump machines and/or central systems

Automated auto-top-up system available with FCM900 Pro version

Data visualisation of metal working fluid conditions

Easy to use interface of secure, tracable live data

New generation comes with touch

Configurable alarm trigger thresholds

Documentation for ISO quality control (10 years)

Simple and quick installation procedure

Health & Safety The equipment is in full compliance with CE-standards.

EQUIPMENT SO LUT I O N S

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FLUIDCONTROL

MIX ING & DISTRIBU TIO N

Recommendation for Use FluidControl is an automated monitoring device that provides realtime measurements on water soluble metal working fluids. It provides live concentration, pH, conductivity and temperature measurements, measures levels and concentration of machines sumps and automatically maintains both the concentration and fluid level.

Technical Specification SPE CI F I CAT I ON Water Inlet Flow Rate

2-6 bar

Internet Connections

LAN/RJ45

Temperature rating

Max 60 deg C

Mains Isolator on / off switch

Yes

Temperature Sensor

Yes

Automatic cleaning system

Yes

Power input

230V 1-phase, 50 Hz

HMI

Touch screen control

Dimensions

395 x 595 x 212 mm

REST API Interface on request For an additional fee we can program a REST API interface so customers can download the raw data from the unit itself, without using the cloud.

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

Tramp Oil Removal Tramp oil is a problem for metalworking fluids in general, and must be frequently removed from the coolant system. Houghton provide various types of tramp oil removal equipment. These range from simple disc and belt skimmers to more elaborate coalescers and high speed centrifuges.

Fines Seperation metal fines are produced. The metallurgical properties of these fines are changed during the cutting process and are now harder than the original material being machined If these metal fines are not addressed by means of filtration, they will be continually picked up by the coolant pumps and re-introduced onto the cutting zone, thus reducing overall tool life and poor surface finishes. These small fines can take hours to settle out of the fluid.

Machine Cleaning Houghton can supply a wide range of equipment to remove or transfer fluid from a machine tool. Consideration must also be given to the correct procedure for machine cleaning. houghton would always recommend the correct usage of system cleaner as part of the sump cleaning procedure.

 FLUIDWORKER  FREDDY VACUUMS  COALESCER  SKIMMER  C-THRU SEPARATOR  FILTRATION  SEPERATION

EQUIPMENT SO LUT I O N S

TREATMENT & MAINTENANCE

When metal is being removed, micron and sub-micron

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

FLUIDWORKER

TRE ATMENT & M AINTENANC E

SIMPLE & SAF E BACTE R I A R E DUCTI O N Description FluidWorker is based on UV technology that keeps bacteria in process fluid under control, secures high productivity and extends the life of the fluid – without exposing employees to allergenic substances or carcinogens. FluidWorker effectively reduces bacteria in process fluids. The fluid is irradiated with UV-C, which reacts with the bacteria’s DNA and makes it unable to reproduce. The bacterial reduction is often very fast, within a few hours 99.9% of the bacteria is decomposed, given dimensioning according to our system analysis.

Features & Benefits \\

Treatment without biocides that can

Easy to use

Stand-alone unit - installed during

cause eczema, allergies, respiratory problems, sterility and cancer – safer

production

for end-user \\

Lower costs – the process fluid gets

a few hours, given correct installation

a longer lifetime and biocide-related

and dimensioning

expenses are avoided \\

Self-cleaning technology – minimum maintenance

Break down 99.9% of bacteria within

Reduced climate footprint – Longer life of the fluid means fewer chemicals in circulation, reduced

Ensures stable production without

waste volumes and fewer transports

downtime - when the process fluid is

associated with this

continuously purified, the quality is maintained and less fluid changes are needed

Health & Safety The equipment is in full compliance with CE-standards.

EQUIPMENT SO LUT I O N S

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FLUIDWORKER

TRE ATMENT & M AINTENANC E

Recommendation for Use

Application

Product is compatible with the full

FluidWorker is the ideal solution for

range of Houghton’s soluble cutting

customers with a larger number of

fluid portfolio. For more information,

metalworking machines with single

please contact your local Houghton

sumps. It is suitable for 500-1500 litre

representative.

tanks with water-based process fluid used for metalworking (machining/ deformation) or surface treatment (quenching/washing).

Technical Specification SYST E M Flow adjustable

2.4 - 5.6 m3/h

Number of UV lamps

Total lamp power

168 - 202 W

Pump power, adjustable

85 - 280 W

Total power consumption

270 - 500 W

Max ambient operating temperature

45OC

Max fluid temperature

45OC

Suitable for tank volume (system and fluid dependent)

0.5 - 1.5m3

Self priming pump

Yes

Lockable on / off switch

Yes

Pressure sensor

Yes

Service timer

Yes

Automatic cleaning system

Yes

On / off via external switch

Emergency stop

Optional inlet filter

Yes

R E ACTOR Material reactor, inlet and outlet pipe

Stainless steel EN 1.4301

IP class

Power input

230V 1-phase, 50 Hz

HMI

5” colour touch screen

D I ME NS I ONS Weight excluding packaging

Approx. 48 Kg

Exterior Dimensions

420 x 360 1340 mm

Lowest possible ceiling height

2400 mm

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

M A R K V • F R E D DY VA C U U M S

TRE ATMENT & M AINTENANC E

M ACHINE CLE ANI NG SYSTE MS. COOL ANT VACUUMS.

Description

Recommendation for Use

FluidWorker is based on UV technology

For the larger models, there is the option

that keeps bacteria in process fluid

of a battery propelled chassis, the Mark

under control, secures high productivity

V can also be battery operated so it can

and extends the life of the fluid – without

be used anywhere and these larger units

exposing employees to allergenic

can be built up to 1000 litres and beyond.

substances or carcinogens.

for any special requirement please

FluidWorker effectively reduces bacteria

speak to your houghton representative.

in process fluids. The fluid is irradiated with UV-C, which reacts with the bacteria’s DNA and makes it unable to reproduce. The bacterial reduction is often very fast, within a few hours 99.9% of the bacteria is decomposed, given dimensioning according to our system analysis.

EQUIPMENT SO LUT I O N S

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M A R K V â€¢ F R E D DY VA C U U M S

TRE ATMENT & M AINTENANC E

Features & Benefits \\

Rapidly removes waste coolant from

Mounted on rugged frame with large wheels and castors

machine sump \\

Easily reversed for discharge

Reduction in machine down time

300 & 500 litre capacity options

Efficiently removes swarf and

Swarf captured within 60 litre filter

fines on contamination from the machine tool

tank \\

Supplied with comprehensive set of

Easily manoeuvred around the shop floor

tools and hoses \\

Rapid discharge of waste fluid

Technical Specification SP E CI F I CAT I ON CAPACITY 310ltr - Length 1955mm, Width 840mm, Height 1530mm POWER UNIT

WEIGHT (EMPTY)

WEIGHT (FULL) A

AIRFLOW WATER

FLOW IN WATER

FLOW OUT

2kW 240v

200

510

2200

270

130

2kW 240v

200

510

2100

250

120

3kW 240v

210

520

2900

270

130

3kW 240v

210

520

2800

260

120

4kW 240v

260

570

3800

250

120

CAPACITY 500ltr - Length 1955mm, Width 840mm, Height 1530mm POWER UNIT

WEIGHT (EMPTY)

WEIGHT (FULL) A

AIRFLOW WATER

FLOW IN WATER

FLOW OUT

2kW 240v

240

740

2200

270

130

2kW 110v

240

740

2100

250

120

3kW 240v

250

750

2900

270

130

3kW 110v

250

750

2800

260

120

4kW 415v

300

800

3800

250

120

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

T H E E C O VA C â€˘ F R E D DY VA C U U M S

TRE ATMENT & M AINTENANC E

M ACHINE CLE ANI NG SYSTE MS. COOL ANT VACUUMS.

Description

Recommendation for Use

The Ecovac is designed to vacuum

For the larger models, there is the option

out coolant from machine tool sumps,

of a battery propelled chassis, the Mark

machine beds, drip trays, conveyors and

V can also be battery operated so it can

even the shop floor with the dedicated

be used anywhere and these larger units

floor tool.

can be built up to 1000 litres and beyond.

The Freddy Ecovac is unique in the coolant vacuum family as it the only

for any special requirement please speak to your houghton representative.

product to vacuum out and recycle the coolant continuously, using an independent pump for return, enabling the metalworking fluid to be recirculated through the filter stage of the coolant vacuum, removing particulates.

EQUIPMENT SO LUT I O N S

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T H E E C O VA C â€¢ F R E D DY VA C U U M S

TRE ATMENT & M AINTENANC E

Features & Benefits \\

Rapidly removes waste coolant from machine sump

Independent pump for discharge

Swarf captured within 37 litre filter basket

Supplied with comprehensive set of tools and hoses

Mounted on four large castors

Rapidly removes waste coolant from

Reduction in machine down time

Efficiently removes swarf and fines contamination from the machine tool

Swarf fines captured within filter basket

Easily manoeuvred around the shop floor

Rapid discharge of waste fluid

Capable to recycle fluid through filter stage

machine sump

Capable of emptying large capacity machines by simultaneously discharging into an IBC

Technical Specification SP E CI F I CAT I ON CAPACITY 200ltr - Length 1210mm, Width 697mm, Height 1350mm POWER UNIT

WEIGHT (EMPTY)

WEIGHT (FULL) A

AIRFLOW WATER

FLOW IN WATER

FLOW OUT

2kW 240v

115

315

2200

270

2kW 110v

115

315

2100

260

3kW 240v

130

330

3000

290

3kW 110v

130

330

2800

280

4kW 415v

165

365

4000

300

CAPACITY 300ltr - Length 1405mm, Width 730mm, Height 1350mm POWER UNIT

WEIGHT (EMPTY)

WEIGHT (FULL) A

AIRFLOW WATER

FLOW IN WATER

FLOW OUT

2kW 240v

135

435

2200

270

2kW 110v

135

435

2100

260

3kW 240v

150

450

3000

290

3kW 110v

150

450

2800

280

4kW 415v

185

485

4000

300

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

TRAMP OIL COALESCER

TRE ATMENT & M AINTENANC E

TR A MP OIL REMOVA L SYSTE MS. MOBIL E TR A MP O I L COAL E SCE R .

Description

Recommendation for Use

The Tramp Oil Separator has been

The floating pick-up skims the tramp oil

designed to combat the problems

and coolant mix from the top of the

associated with tramp oil levels in

machine sump.

machine tool coolant systems.

As the liquid moves slowly through the

The Tramp Oil Separator is easily

coalescing media, oil droplets are

manoeuvrable, so it can be used

separated from the coolant and rise

throughout the factory workshop, and

to the top of the unit. When the oil

it runs continuously so not to interfere

layer builds up sufficiently in the unit,

with production, siphoning the tramp

it passes over a weir, and is held within

oil into the supplied collection bottle,

the collection containers away from the

and allowing the cleaned coolant to be

clean coolant.

returned.

Coolant, cleaned of contaminated oils, is returned directly to the machine sump via gravity.

EQUIPMENT SO LUT I O N S

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TRAMP OIL COALESCER

TRE ATMENT & M AINTENANC E

Features & Benefits \\

Tramp oil separation via efficient

variety of applications

coalesce system \\

35 litre of fluid media held in removable baskets

Easily moved very mobile

Easy setup of input and output connections

Cleaned fluid runs back via gravity to

Removes tramp oil from coolants in a

Runs continuously

Variety of filters and floats available

Extends coolant life

Reduces coolant waste volumes

Improves operator working environment

machine tool sump

Technical Specification SPE CI F I CAT I ON Dimensions Length 800 x width 516 x height x 1185mm Weight approximately 75kg when empty 145kg when full 70 litre capacity tank Finished in oil and acid resistance powder coating paint Containers to hold removed tramp oil

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

TRAMP OIL SKIMMER

TRE ATMENT & M AINTENANC E

TR A MP OIL REMOVA L SYSTE MS. TR A MP OIL SKI MME R S. Description A simple method to remove unwanted tramp oil in coolants and parts washers, the tramp oil skimmer is a compact unit that can be used even through the 2 inch bunghole of a 205 litre drum. Due to its low weight and easy installation it can easily be moved from one application to another. The unit is durable and strong constructed from sturdy 304 stainless steel with long life fan-cooled motor and built in 24 hour timer.

Features & Benefits \\

Fan cooled motor

Continuous operation

25 & 50mm specially engineered

High tramp oil removal rate

Suitable for a variety of applications

plastic belts

and environments

Both sides of belt wiped

304 stainless steel base and housing

Spring loaded stabiliser bar

1.0m discharge hose and clamp

Integrated 24 hour timer

Belt always under tension improving tramp oil removal

Can be timed to operate when machine not running

Technical Specification SPE CI F I CAT I ON

EQUIPMENT SO LUT I O N S

Belt width

25 and 50mm specially engineered plastic belts

Discharge hose

1 meter clear discharge hose and clamp

Electrical lead

2.4 meter grounded power cord with plug

Belt drops available

150; 300; 450 & 600mm

Voltage option

110 & 230 volt available

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C - T H R U S E PA R ATO R

TRE ATMENT & M AINTENANC E

TR A MP OIL REMOVAL SYSTE MS. C- THRU SEPAR ATO R .

Description

Recommendation for Use

The C-Thru® Separator is a unique,

The C-Thru® Separator is compact

patented unit designed to remove solid

and portable with installation made

and liquid contamination from emulsion

simple by attaching directly to the

coolants and cleansing baths. It is

machine utilising the magnetic base

used throughout the metalworking and

provided. A float connected to a pump

pre-treatment industries to remove

(electric or air) draws the contaminate

every type of oil pollution (hydraulics,

oil from the surface or fluid. The tramp

lubricants, sliding and

oil is separated and remains in the

anti-corrosion oils, etc.), which have

C-Thru® Separator where it can be

emulsified or are covering the surface

drained off by opening the valve. Pump

of emulsion coolant tanks and cleansing

options available 110 volt 240 volt and

baths.

compressed air.

Features & Benefits \\

Tramp oil separation via efficient

Transparent tank shows performance of unit

coalesce system \\

Easy installed using magnetic plates

No consumables

Compact no floor place utilised

Easy to maintain

Rapid removal of tramp oil compared to traditional belt skimmers

Aid to maintaining coolant in optimal condition

Extends coolant life

Reduces coolant waste

Technical Specification SP E CI F I CAT I ON Dimensions

Length 47mm x Height 363 x Width 119mm, Tank capacity 10L

Material

Engineered thermoplastic resin

Pump type

Electric/compressed air

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

F I LT R AT I O N

TRE ATMENT & M AINTENANC E

F INES SEPAR ATI O N. MOBIL E OF F L IN E F I LTR ATI O N SYSTE M.

Description

Recommendation for Use

Oil and coolant cleanliness is critical

For oil, a depth filter is used made of

to the reliability and conformity of the

long fibre cellulose that will absorb

machining process and will extend

free water, as the oil passes through

the coolant life. The mobile system is

the element minute particles of

configured for offline filtration which

contamination are extracted from the

can be temporarily or permanently

oil by adhering to the many surfaces of

installed and works independently of the

the filter.

system being filtered, relying on its own integrated pumps to provide pressure and flow through its own filters.

For water based fluids an alternative element made of chemically inert wound polypropylene fibre is utilised, capable

With an offline system an optimum flow

of removing micro particles, and tramp

rate can be achieved which will be at a

oil, without effecting the stability of

controlled rate and pressure allowing

emulsions.

very high levels of cleanliness to be achieved. By continuously removing tramp oil and particulate contamination the negative effect on the coolant emulsion is minimised thus extending the coolant life and will help maintain the fluid within specification.

EQUIPMENT SO LUT I O N S

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F I LT R AT I O N

TRE ATMENT & M AINTENANC E

Features & Benefits \\

Intelligent PLC control

High / low pressure cut off

Filter element change timer

Large capacity pre-filter with re-

water contamination \\

Increases system reliability

Prevents system corrosion

usable filter bag

Reduces component wear

Integrated sample points â€“ allows

Extends oil life and generates

CO2 savings

Reduces operating costs

connection to particle monitor / oil sampling \\

Removes free and dissolved

Removes varnish and microparticles (down to less than 1 micron)

Technical Specification SPE CI F I CAT I ON Dimensions length 1036 x width 554 x height x 984mm Weight when empty 120kg Flow rate 500 litres per hour Maximum system capacity to treat 5000 litres Pump suction lift self-priming 5.5 meters IP rating IP55 Max operating 60 C Voltage 230 volt NB: A range of mobile offline filtration systems are available varying in flow rate and system capacity.

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

S E P E R AT I O N

TRE ATMENT & M AINTENANC E

F INES SEPAR ATI O N SYSTE MS. MOBIL E CENTR I F UGE . Description The Centrifuge works by spinning dirty coolant which then compacts the contaminants into a cake on the wall of the rotary liner, the cleaned coolant then returns to its machine tool. It filters down to 5 micron and has throughput levels up to 80 litres per minute.

Features & Benefits \\

Maximum throughput of 80 litres

Recycles coolant and extends coolant life

Enhances coolant performance and

per minute \\

Filter performance to 5 micron

Suitable for a wide variety of cutting

production quality \\

Improves and extends tool life

Significantly cuts waste disposal costs

Removes contaminants that cause

oil and coolants \\

Mobile easily moved from machine to machine

bacterial growth

No consumables \\

Filters down to less than 5 microns

4 litre bowl capacity

Technical Specification SP E CI F I CAT I ON Flowrate 80 litres per minute Filter performance to 5 micron Single Bowl: Length: 680 x Width 610 x Height 560mmz Power required 415v 3 phase Weight (empty) 125 A Double bowl version is available

EQUIPMENT SO LUT I O N S

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FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

Lorem ipsum dolor sit amet, consectetur adipiscing elit. Praesent leo justo, dignissim ac purus in, finibus tristique lectus. Nunc mollis aliquet ligula, at suscipit ipsum sagittis nec. Vestibulum in libero nunc. Nunc mollis aliquet ligula, at suscipit ipsum sagittis nec. Vestibulum in libero nunc. Lorem ipsum dolor sit amet, consectetur adipiscing elit. Praesent leo justo, dignissim ac purus in, finibus tristique lectus. Nunc mollis aliquet ligula, at suscipit ipsum sagittis nec. Vestibulum in libero nunc. Nunc mollis aliquet ligula, at suscipit ipsum sagittis nec. Vestibulum in libero nunc.

 MIST EXTRACTION  LEV TESTING  AIR MONITORING  SPILL MANAGEMENT

EQUIPMENT SO LUT I O N S

ENVIRONMENTAL HEALTH & SAFETY

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FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

MIST EXTRACTION

ENVIRO NMENT, HE ALTH & SFAETY

OIL MIST F ILTER S AND NE AT O I L MI ST CO L L E CTO R S. Description Exposure to airborne oil mist can cause

Our standard product range is extensive -

a number of health issues, as well as

including everything from small stand-alone

posing a slip and fire hazard. Filtermist

units with a nominal airflow of 500 m3/h (for

provides stand-alone and centralised

installation directly on the machine tool)

extraction systems depending on which

to larger units capable of extracting up to

is the best solution for each individual

8,000 m3/h. As an alternative to our standard

customer.

range, bespoke units can be manufactured to

Filtermist has specialised in effective oil mist extraction since 1969 and is

form a centralised system designed to take care of an entire production site.

trusted by some of the worldâ€™s leading

Products fall into two main types - those

manufacturers to effectively remove

designed to suit water-soluble based

oil and coolant mist from the air in their

coolants (used in applications such as

workshops. Oil mist filters are designed

machining, grinding, turning and milling)

to collect and filter oil, water-soluble

and units for oil smoke generated from neat

and synthetic coolant mists from a

oil applications (used in processes such as

variety of machining operations and

cold heading, heat treatment and forging

other industrial processes - reducing the

operations).

risks of mist related hazards.

S SERIES

FX SERIES

ULTRA-COMPACT OIL MIST FILTER

COMPACT OIL MIST FILTER

Filtermistâ€™s S Series oil mist filters are

FX oil mist filters are available with a number

compact, lightweight and designed to be

of mounting options including floor stands,

directly mounted onto machine tools. They

machine mounts and the mobile CSX unit.

can also be fitted using floor stands and machine mounting brackets.

designed to operate efficiently on a wide

S Series oil mist filter units are low energy

range of industrial power supplies.

filters are available in standard mild steel construction and also stainless steel versions for use in hazardous or corrosive environments.

EQUIPMENT SO LUT I O N S

more than 60 countries worldwide and are

Fitted with either 0.18kW or 0.55kW motors, users. Filtermist FX and S series oil mist

Filtermist oil mist filter units are used in

Filtermist FX and S series oil mist filters are available in standard mild steel construction and also stainless steel versions for use in hazardous or corrosive environments.

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MIST EXTRACTION

ENVIRO NMENT, HE ALTH & SFAETY

A•MIST

S FUSION

OIL MIST FILTERS FOR LARGE MACHINES AND CENTRALISED SYSTEMS

NEAT OIL MIST COLLECTOR S Fusion successfully removes submicron

Absolent A•mist oil filters guarantee a

particles generated in neat oil applications

high separating efficiency, which does not deteriorate even over long periods of operation. The filters have been designed to comply with future requirements, rather than present day requirements, and are therefore a wise investment.

by combining a hi-tech synthetic selfdraining media filter with Filtermist’s proven centrifugal technology - offering an effective alternative to other products in the highpressure coolant market. Machine mounted to free up valuable floor space.

The filter cassettes have a very long operating life in order to minimise servicing and maintenance costs, and they can run 24 hours a day.

Lower initial outlay and running costs than comparable filtration systems. Airflow reduced by just 14% in 4000 test hours.

Technical Specification M ODE L

A I RFLOW M 3 /H R

M OTO R

S200

180 @ 50Hz 215 @ 60Hz

0.18kW 50Hz 200v, 220v, 380v, 400v, 415v

0.18kW 60Hz 200v, 220v, 230v, 440v, 460v, 480v

S400

425 @ 50Hz 500 @ 60Hz

0.55kW 60Hz 200v, 220v, 380v, 400v, 415v

0.55kW 60Hz 200v, 220v, 230v, 440v, 460v, 480v

S800

800 @ 60Hz 950 @ 60Hz

0.55kW 50Hz 200v, 220v, 380v, 400v, 415v

0.55kW 60Hz 220v, 230v, 440v, 460v, 480v

FX4002

1250 @ 50Hz 1500 @ 60Hz

1.1kW 50Hz 200v, 220v, 380v, 400v, 415v

1.1kW 60Hz 200v, 220v, 230v, 440v, 460v, 480v

FX5002

1675 @ 50Hz 2000 @ 60Hz

1.5kW 50Hz 200v, 220v, 380v, 400v, 415v

1.5kW 60Hz 200v, 220v, 230v, 440v, 460v, 480v

FX6002

2000 @ 60Hz 2400 @ 60Hz

2.2kW 50Hz 200v, 220v, 380v, 400v, 415v

2.2kW 60Hz 220v, 230v, 440v, 460v, 480v

FX7002

2750 @ 50Hz

2.2kW 50Hz 200v, 220v, 380v, 400v, 415v

Not available

S SERIES

FX SERIES

M ODE L & M A X . P E R M ISSIBLE AIR VO LU ME M 3 /H R A•MIST SERIES A•mist6C - 600, A•mist10C - 1000, A•mist80C - 8000, A•mist10 - 1000, A•mist20 - 2000, A•mist40T - 4000, A•mist40TF - 4000, A•mist60 - 6000, A•mist80T - 8000, A•mist80TF - 8000

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

LEV TESTING

ENVIRO NMENT, HE ALTH & SFAETY

REGUL AR LEV TE STS BY A CO MPE TE NT PE R SO N A R E A L EGAL REQUI R E ME NT O F CO SH H ( CO NTR O L O F SUBSTANCES H A Z AR DO US TO HE A LTH ) R E GUL ATI O NS. Description What is local exhaust ventilation testing

LEV systems must be tested every 14

(LEV testing)?

months

According to the HSE’s Occupational

CoSHH regulations require most LEV systems

Lung Disease in Great Britain 2017

to be thoroughly tested at least once every

report, 12,000 lung disease deaths

14 months. This applies to all oil mist, welding

each year are estimated to be linked to

fume, smoke and dust extraction units that

past exposures at work. This has led

you currently have on site. This examination

to increasingly stringent guidelines

must be undertaken by a competent person

and statutory requirements for Local

and the tests and reports must conform

Exhaust Ventilation (LEV).

to HSE standards. HSG258 provides the

HSE published the third edition of HSG258 ‘Controlling airborne

recommended procedures to achieve these statutory requirements

contaminants at work: A guide to local exhaust ventilation (LEV)’ in 2017. This guide provides guidance on the design of new local exhaust ventilation (LEV) equipment. It describes the principles of deciding on, designing, commissioning and testing effective LEV.

EQUIPMENT SO LUT I O N S

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LEV TESTING

ENVIRO NMENT, HE ALTH & SFAETY

Recommendation for Use Expert analysis and practical recommendations We provide comprehensive LEV

allows us to provide practical advice and

Testing for all makes and types of

recommendations.

extraction equipment, working strictly in accordance with HSG258l guidelines. LEV Tests include measuring the air flow speed (velocity) of the air being extracted at the source and in the ducting. The results are compared with the requirements specified in the original system design and our expert analysis, based on 50 years’ experience in the manufacture and design of LEV systems,

LEV reports include photos and/or schematic diagrams showing the Test Points, which are also clearly identified on the ducting, as required by the HSE. LEV Testing is a legal requirement for compliance with health and safety standards and test reports often form part of a company’s insurance. Inadequate testing can result in employers being prosecuted, insurance being invalidated and employees falling ill.

Application

Note

Monitoring equipment and record

LEV Considerations

keeping

record keeping systems as specified in HSG258 can be supplied as part of our

LEV Tests should be carried out at least once every 14 months.

Air flow monitoring equipment and \\

Some applications require more frequent testing.

service. \\

Tests must be undertaken by a

Air Flow Indicators

Smoke Sticks

LEV Log Book

company’s insurance requirement.

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H OUG H TON IN T E R NAT ION A L

competent person. \\

The test report may form part of a

AIR MONITORING

ENVIRO NMENT, HE ALTH & SFAETY

L EV AIR F LOW MO NI TO R I NG A ND R E CO R D K E E PI NG. Description The Health and Safety Executive HSG248 guidelines on Controlling Airborne Contaminants at Work covers recommended methodologies, record keeping procedures, air flow measurement and testing equipment. Filtermist service programmes for all makes and types of extraction equipment include these best practice procedures and provide a full range of recommended equipment covering:

AIR FLOW INDICATORS

SMOKE STICKS

Filtermist offers air flow gauges as an option

Filtermist Smoke Sticks are designed

on all extraction equipment as recommended

for easy testing of air flow in workplace

in HSG258, as well as F Monitor – Filtermist’s

extraction systems as specified in HSG258.

dual monitoring system.

A thin smoke pattern that lasts for several

Gauges and F Monitors can be retrofitted to any existing LEV system, including dust, welding fume, smoke and oil mist extraction units. Air flow indicators offer the equipment operator an accurate, immediate and easy to read indication of whether the extraction system is working efficiently. CoSHH regulations require employees to report any

hours allows testing for the slightest air movement on extraction systems. They are supplied with a purpose designed holder and being clean and non-corrosive, can be used safely in areas with electronic equipment and unprotected metal surfaces. This product has an extremely long shelf-life and is very safe to use.

defects in LEV Systems ‘forthwith’ – using monitoring devices makes this requirement easy to adhere to.

LEV LOG BOOKS A series of daily, weekly and monthly checks

WIND DIRECTION INDICATOR BOTTLES

should be carried out on all LEV equipment

Filtermist’s dedicated LEV Engineers also

designed Log Books to allow accurate

use wind direction indicator bottles to

recording of these LEV checks, together with

ensure extraction systems are performing

comments on any corrective action required.

as intended. These offer an alternative to

A separate section for regular maintenance

smoke sticks in environments where naked

and unplanned repair work is also included.

flames are not permitted.

These records can then be used as evidence

in order to comply with guidelines published in HSG258. Filtermist offerd specifically

that HSE guidelines are being followed.

EQUIPMENT SO LUT I O N S

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FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

SPILL MANAGEMENT

ENVIRO NMENT, HE ALTH & SFAETY

INNOVATIVE TECHNO LO GY AND TOP QUAL ITY SPI L L SO L UTI O NS.

Description Spill Centres are convenient, handy and

and socks in whichever format suits your

always ready to go no matter how big

business. Ask us about our replenishment

or small the spill. Ecospill Spill Centreâ€™s

service that keeps your Spill Centre well

can come pre-stocked with pads, a roll

stocked and always ready for action.

SPILL PADS

SPILL RESPONSE KITS

You can use Ecospill absorbent pads

Our spill response kits have been designed to

anywhere that fluids have leaked or spilt.

offer the best protection from any spill.

Even selecting the right grade has been made easy. For most indoor applications the black/grey pads are great. Use them to absorb most fluids, including oils, fuels,

Each and every spill response kit is manufactured to the best ability, from the product picked to the packaging it arrives in.

solvents, coolants, water and foodstuffs such as milk or wine. If there are any aggressive fluids such as acids or alkalis around, go for yellow. And if the spill is outdoors and itâ€™s oils or fuels, use white. These repel water, so are ideal for spills that have reached watercourses such as rivers, ponds or drains.

EQUIPMENT SO LUT I O N S

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SPILL MANAGEMENT

ENVIRO NMENT, HE ALTH & SFAETY

SPILL CENTRES Our spill centres are available in a steel or plastic cabinet for maintenance, oil-only and chemical absorbents. Spill Centres are a great way to keep your premises protected at all times with the benefit of our team stocking them up for you when youâ€™re running low and need a refill.

ACCESSORIES The additional equipment range is designed to compliment all your needs and make your spill control easier to manage. With our wealth and knowledge, the Ecospill team will be able to help you with your accessory needs.

SPILL & GO The Spill & Go Dispenser Box has unique integral tabs so that it can be affixed to a wall or kept on a work bench for ease of access. The Spill & Go Spill Kit is ideal fo dealing with small scale spills and leaks around the workplace. All formats are available in Maintenance Oil Only and Chemical versions.

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H OUG H TON IN T E R NAT ION A L

 BRIQUETTING  FINE PARTICLE SEPERATION  COOLANT MANAGEMENT SYSTEMS

EQUIPMENT SO LUT I O N S

COST RECOVERY

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FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

BRIQUETTING MACHINES

C O ST REC OVERY

TURNING WASTE PR O DUCTS I NTO USE AB L E AND PROFITABL E B R I Q UE TTE S.

Description The days of your waste materials taking

and more economical to recycle or sell to

up valuable space, time and resources

foundries. Metal briquetting also enables

are coming to an end. Industrial

you to reclaim the fluids – oil, lubricants and

briquetting is a process that makes

other liquids – used in your metalworking

your life easier. But, what is a briquette

processes.

machine and does it work with my materials? We are glad you asked!

specific requirements. These aren’t the

press, turns waste material into uniform-

huge, noisy metal briquetters of the past.

sized briquettes that are easy to store

All systems are engineered for automatic,

and, in many cases, can be sold to

24-hour operation with low horsepower,

generate revenue. You can make your

compact designs that allow for easy

waste problems a much smaller part

integration into existing production lines. In

of your business, and can improve your

addition to keeping your workplace cleaner

bottom line by reducing storage and

and saving space, metal briquetting helps

handling costs and increasing income at

your company meet sustainability goals.

the same time.

Metal briquetting turns your production

the volume by as much as 20-to-1, making scrap infinitely easier to handle

EQUIPMENT SO LUT I O N S

metal briquetting systems to meet your

A briquette machine, or a briquetting

Briquetting your scrap can reduce

We offer a number of hydraulically powered

waste into valuable products for heat generation, supports your recycling initiatives and reduces your carbon footprint.

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BRIQUETTING MACHINES

C O ST REC OVERY

Features & Benefits \\

Runs operator-free

Operated hydraulically

Controlled by a programmable logic

your plant floor \\

Sell resulting metal briquettes

Reclaim value from cutting fluids (oil,

Engineered for automatic, 24-hour operation with low horsepower

controller (PLC) \\

Compact design for easy integration into

Ready to handle and transport right out of the press

lubricants) from metals

Application

Recommendation for Use

Salvage more value from your scrap

How our briquetters turn your scrap into

materials, including:

briquettes:

Aluminum

Steel

Brass

Tire wire

Bronze

Titanium

Cast-iron

Zinc

Copper

Most other metals

Magnesium

The briquetter is loaded with residual waste.

The material is transported into the pre-charging chamber by a conveying screw.

The pre-charger presses the material into the main pressing chamber (to ensure consistent briquette size).

The main pressing ram compresses the material into the mold and forms the briquette into its final shape and density.

The reciprocating mold moves sideways and the briquette is ejected by parallel ejectors as a second briquette is formed.

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

i S WA R F B R I Q U E T T I N G M A C H I N E

C O ST REC OVERY

A HIGHLY EF F IC I E NT SO L UTI O N, CO NV E R TI NG E XPE N S I VE PROD UCTION WASTE I NTO R E USAB L E M ATE R I ALS.

Description This machine series combines the

in energy efficiency. For example, with only 4

advantages of a compact space-saving

kW hydraulic power, up to 200 kg/h of metal

machine with the advantages of a large

shavings can be compressed.

briquetting press with high briquetting performance. The machinery can be equipped to meet the individual requirements and needs of the customer.

A PLC-controlled automated briquette length function guarantees a maximum throughput rate at all times. A large touch panel allows easy operation. The compact and ready-tooperate models in this series are supplied

Briquette diameters of 50-100 mm and

as complete presses with a solid frame

throughput rates of 60-600 kg/h allow

construction and an integrated hydraulic

for customised briquetting solutions.

unit. Numerous options extend the scope of

The optimised hydraulic system

application and complete the range.

contributed to a considerable increase

Features & Benefits \\

Compact and space-saving design

Adjustable compression pressure

Easily adjustable briquette density

Low wear due to optimised

Lower storage, transportation and disposal resources

briquettes \\

compression zone \\

No assembly required â€“ supplied

Savings of up to 95% on new oil or emulsion quantities

EQUIPMENT SO LUT I O N S

Sustainable and environmentally friendly operation

ready to plug in \\

Added value through the sale of metal

Almost complete prevention of corrosion of metal shavings

Briquettes with low residual moisture for optimal melting

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800

Â« Visualisation example

1560

800

BrikStar iSwarf 440-10-3SN-WA

330

750

970 (208)

(208)

1000

575

1322

2150 1000

440

1800

1000

200

265

BRIQUETTING MACHINES

C O ST REC OVERY

Technical data

Dimensions & Schematics

Typ

BrikStar iSwarf 440

Technical Specification50 -70 mm Briquette diameter Briquette length Drive motor hydraulic

SPE CI F I CAT I ONAluminium Output Steel and cast non ferrous-metal Briquette diameter

60 -100 mm

40 - 80 mm 4 / 5,5 / 7,5 kW

iSWARF 60 -180 kg/h

BrikStar iSwarf 550

50-110 mm

440

5,5 / 7,5 / 11 kW

i SWARF 550 120 - 400 kg/h

120 -280 kg/h

150 -550 kg/h

15050-70 -300 kg/h mm

180 -600 kg/h 60-100 mm

Briquette length

40-80 mm

50-110 mm

Drive motor hydraulic

4/5,5/7,5 kW

5,5/7,5/11 kW

Output - Aluminium

60-180 kg/h

120-400 kg/h

Output - Steel and cast

120-280 kg/h

150-550 kg/h

Output - Non ferrous-metal

150-300 kg/h

180-600 kg/h

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

F I N E PA R T I C L E S E P E R AT I O N

C O ST REC OVERY

A SEPAR ATOR ENAB L I NG SE PAR ATI O N O F PAR TI CL E S O F SIZES DOW N TO 10µ ( O PTI O N 3µ ) BY SE TTL I NG THE M I N A MOTIONL ESS L I QUI D VO L UME . Description A separator enabling separation of particles of sizes down to 10µ (option 3µ) by settling them in a motionless liquid volume. Small particles, which accumulate in process fluids particularly hard metal grinding, are difficult to separate in a liquid which is moving. However by settling out particles in a motionless volume it is quite possible to attain high levels of separation with particle as small as 3µ.

The lamella package is sized according to process flow rate and has a built in

This is the working principle of

automatic self cleaning system. Separated

our Decantor Separation System.

particulate in the form of sludge is collected

Periodic settling of the carrier fluid in

automatically in standard 200 litre drums.

a motionless liquid volume installed

Total throughput capacity up to 2000 litres/

with a lamella package provides an

min.

environment where the smallest particles are allowed to separate.

As with all our systems the Decantor is classed as a lean maintenance unit, once

The Decantor is equipped with

set up it requires little in the way of human

clean tank, dirty tank, supply pumps

intervention and uses zero consumable

and automatic topping-up system.

media.

Technical Specification SPE CI F I CAT I ON Application: Hard metal grinding, honing, EDM fluids Separation quality: Down to 10µ (option 3µ) Throughput capacity: Up to 2.000 lpm/unit

EQUIPMENT SO LUT I O N S

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FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

COOLANT MANAGEMENT SYSTEM

C O ST REC OVERY

DINOS AURUS CO O L A NT M ANAGE ME NT SYSTE M.

Description Our Dinosaurus range of separators

Zero consumable media also means that

solve the issues associated with tramp

each system can be described as lean

oil and particulate contamination in

maintenance, the central plant needs no daily

water mix cutting coolants. Consisting

input from operatives.

of a three phase lamella separator built into a central coolant management system they operate around the clock to deliver and return coolant to every machine tool on the shop floor.

However the Dinosaurus range provides much more than the removal of tramp oil and sludge. Connected to a factory wide supply and return pipeline system coolant is delivered to each machine tool at the

The lamella plate package in the central

correct dilution while each machine tool

unit removes floating particulate and

sump is maintained at exactly the right level

tramp oil before delivering clean coolant

to ensure optimum coolant performance.

back to process. Tramp oil is held in a

This means that coolant dilution across

dedicated tank within the system while

the shop floor remains consistent and is

particulate, collected as sludge, is

easily checked at the central unit where

removed by a scraper.

adjustments cam be made manually

The coolant management system includes: self cleaning 3-phase lamella separator, dirty tank, clean tank, supply pumps, sludge conveyor and automatic

or automatically. Clearly labour costs associated with such tasks as cutting fluid control and delivery can now be removed from the process.

top up/mixer system.

EQUIPMENT SO LUT I O N S

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COOLANT MANAGEMENT SYSTEM

C O ST REC OVERY

Application

CENTRAL UNIT

RETURN PUMP MODULES

Each coolant management system is sized

Each machine tool sump needs a return

according to the number of machine tools to

pump module to pump coolant back to the

be connected. The more machines the larger

separator. A float valve continually feeds

the central separator. Coolant flow rates are

coolant into each machine connected to

more or less infinite, the smallest Dinosaurus

the system while the return pump removes

starts at 500 litres/min but can rise to

floating tramp oil and particulates. The plant

thousands depending on client needs. This

operates 24/7 which means even the largest

one is a 500 litre/min unit and can service up

sumps are circulated many times per day

to 50 machine tools.

leaving coolant fresh and clean. Should the

Each separator is equipped with an automatic cleaning cycle, topping up/mixer system, drag link conveyor to remove sludge

return pump fail for any reason the resulting rise in coolant level closes the float valve leaving the machine safe from overflow.

deposits along with supply and circulation

This way every machine tool connected

pumps. Sludge handling systems can be

operates are the correct dilution and sump

incorporated as shown, de-watered sludge

levels are always maintained. The result is

systems are also available automatically

trouble free coolants which can last years

feeding recovered coolant back to the

before any change is necessary.

process.

PIPEWORK INSTALLATION Overhead pipework system delivers and returns coolant automatically eliminating the need to continually top up and monitor machine tool levels and dilutions. Pipework design will allow total flexibility so that when machine tools need to be moved or replaced its a simple matter of disconnection and reconnection without the need for pipework modification. Our installation teams use light weight â€˜Mapressâ€™ which requires no hot work and produces a very professional finish.

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

COOLANT MANAGEMENT SYSTEM

C O ST REC OVERY

DINOFILTER COO L A NT M A NAGE ME NT SYSTE M. Description DinoFilter Coolant Management systems consists of one or several filter cassettes which are located in the central units. Contaminated fluid returned from the process enters the filter tank where it is passed through the filter mesh on each cassette. Solid particulate, which cannot pass through, builds into a filter cake on the outside of the filter mesh. Clean fluid is pumped to the clean tank where it is returned to process. Each cassette is automatically closed down at intervals to allow the filter cake to be removed where it is discharged from the central plant by scraper. The filter mesh is constructed from acid

that should it be necessary to remove one for any reason the production process can continue unaffected. This makes the DinoFilter a perfect fit for full flow systems where the entire production process is reliant on 100 % up-time.

proof stainless steel to provide for a

The number of filter cassettes in each

long service life. Each cassette operates

DinoFilter is dependent upon the flow rate

independently of the others meaning

required in the process.

Features & Benefits \\

Zero use of consumable media

(paper) reducing waste to only that

fluids containing fibrous materials e.g.

generated in the process.

steel grinding.

Limited number of moving parts

aluminum or steel chips from the cutting

requirement.

process.

Modular construction enables a affecting filtration or production.

EQUIPMENT SO LUT I O N S

Ideal for full flow systems collecting

leading to a lean maintenance

Flow rates up to 10,000 litres/min can be specified.

cassette to be removed without

Outstanding efficiency when clarifying

Automatic Topping Up & Mixing system

Full PLC Control and Diagnostics.

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COOLANT MANAGEMENT SYSTEM

C O ST REC OVERY

Application CENTRAL UNIT Each DinoFilter coolant management system

Sludge handling systems can be incorporated

is sized according to the number of machine

as shown, de-watered sludge systems

tools to be connected. Overall flow rate

are also available automatically feeding

required will determine the size of each

recovered coolant back to the process. The

cassette and how many will be needed.

DinoFilter is ideal for full flow systems where

Each DinoFilter coolant management system is sized according to the number of machine tools to be connected. Overall flow rate

up time has to be 100% owing to individual maintenance on one cassette having no effect on filtration or production.

required will determine the size of each

Each cassette is equipped with an automatic

cassette and how many will be needed.

cleaning cycle controlled by PLC as are the

Each DinoFilter coolant management system is sized according to the number of machine tools to be connected. Overall flow rate required will determine the size of each cassette and how many will be needed.

other functions of the DinoFilter system. Sludge handling systems can be incorporated as shown, de-watered sludge systems are also available automatically feeding recovered coolant back to the process. The DinoFilter is ideal for full flow systems where

Each cassette is equipped with an automatic

up time has to be 100% owing to individual

cleaning cycle controlled by PLC as are the

maintenance on one cassette having no

other functions of the DinoFilter system.

effect on filtration or production.

RETURN PUMP MODULES

PIPEWORK INSTALLATION

As the DynoFilter is well suited to process’s

Overhead pipework system delivers and

where high levels of sludge are encountered,

returns coolant automatically eliminating

for example grinding systems, usually

the need to continually top up and monitor

they are installed ‘full flow’. Therefore the

machine tool levels and dilutions. Pipework

DynoFilter output has to match the entire

design can allow total flexibility so that when

flow rate needs of a machine shop. This

machine tools need to me moved or replaced

means that each machine tool will need a

its a simple matter of disconnection and

Vortex Return Tank to pump coolant back

reconnection without the need for pipework

to the DynoFilter. Usually existing individual

modification. Our installation teams use light

sump systems, consisting of consumable

weight ‘Mapress’ which requires no hot work

media or hydro-cyclone systems, are

and produces a very professional finish.

removed and replaced with a single return tank to collect contaminated fluid from the process. Where high pressure delivery systems are needed these can be provided at each machine tool as part of the mew installation.

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

Evaporation technology is a clean method of separation and for this reason it has become recognised as BAT (Best Available Technology) in European directives for the treatment of waste coolant and wash fluids. The evaporation process is very robust and can process all types of water based coolant and wash media effluent waste. Vacuum Evaporation will generate a reduction of water based waste to approximately 90%, producing an aqueous phase which can be reused in none critical operations such as floor cleaning or discharged direct to the foul drain with the consent of the water authority. The remaining concentrate, which will be oil rich, is collected for disposal via a waste contractor. Houghton has considerable experience in this area of waste management having installed numerous vacuum distillation systems and can advise on the suitability of such a system to your waste streams.

ď ” VACUUM EVAPORATORS ď ” EVAPORATORS

EQUIPMENT SO LUT I O N S

WASTE TREATMENT

As the cost of fluid disposal continues to rise and organisations come under increasing pressure to improve their environmental credentials, operating an onsite waste treatment process becomes a more viable option for companies.

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VA C U U M E VA P O R ATO R S

WASTE TRE ATMENT

HIGHLY REL IABL E E VA PO R ATO R S, E F F E CTI V E I N REDUCING WASTE WATE R VO L UME A ND PR O DUCI NG A HIGH QUAL IT Y, R E USAB L E DI STI L L ATE . Description The Vacuum Evaporators are fully automatic standardised units, low in energy consumption and with a low CO2 footprint. Capacities range from 1 to 200 tons per day of distillate from wastewater treatment. The vacuum evaporators are designed to produce maximum distillate quality with minimum capital and operating costs. Each model is a compact skidmounted unit, simple, safe and easy to move. Control is by a PLC, including the functions of feed and discharge, therefore allowing automatic operation and minimum supervision. All models are designed for continuous operation, 24h/ day, and require just electrical supply and compressed air.

Features & Benefits \\

Disposal cost reduction

Wastewater volume reduction

Water recycling and reuse

High level of automation

suit waste stream

Option for remote control

Designed for 24 hour operation

Maximum water recovery, minimum

Energy within the process recycled

Automatic discharge of concentrate

Capable of reducing water based waste streams by 90%

Evaporation undertaken at vacuum reducing boiling point

EQUIPMENT SO LUT I O N S

Operating conditions controlled to

quantity of waste to be disposed of \\

Low energy consumption

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VA C U U M E VA P O R ATO R S

WASTE TRE ATMENT

Technical Specification SPE CI F I CAT I ON M ODE L PC F 2.4 Z Nominal production of distillate with water

2400 [l/24h]

Construction

Pre-assembled single module on a stainless steel frame

Distillate temperature

30-40 °C

Refrigeration fluid

R 134a

Electrical cabinet rating

IP 54

Electrical specific consumption per litre

151 [Wh/l] ± 10%

of distillate Dimensions

L1770 x W 1170 x H 2350mm

Note There is a range of these units available varying in the quantity of waste to be treated all built on a modular design and skid mounted for ease of siting and use.

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

H OUG H TON IN T E R NAT ION A L

E VA P O R ATO R S

WASTE TRE ATMENT

AQUA- S AVE IS A F UL LY AUTO M ATI C WASTE WATE R TRE ATMENT SYSTE M R E Q UI R I NG NO O PE R ATO R I NPUT AND MINIM AL M A I NTE NANCE O R SE RV I CE .

Description At the heart of the system is the

The system is designed for continuous

evaporation unit, which operates at

treatment 24 hours a day, 7 days a week.

80°c – 85°c. The processing conditions have been established to evaporate the aqueous part of the process solution, with the retention of the higher

which can be set to suit each application. The reclaimed water is neutral, permitting

contaminants. The operating conditions

re-use or disposal to main drain, subject to

can be tightly controlled to suit the

permission.

contained within the process solution.

EQUIPMENT SO LUT I O N S

automatically discharged at regular intervals,

boiling water soluble oils and other

particular nature and proportion of the oil

The waste oil is concentrated and

The energy used in the process is recycled, making the system highly energy efficient.

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E VA P O R ATO R S

WASTE TRE ATMENT

Features & Benefits \\

Fully enclosed self bunded

Fire rated options available

All sumps compliant with

No need for civil bund

No requirement to maintain integrity civil

UK regulations \\

bund via bund inspections

25, 205 and 1000 litre container storage

Secure storage of fluids

Large range of standard sizes available

Conform to environmental legislation

Controlled access to fluids

Units available to suit different amounts of containers

Bespoke variants available

Suitable for indoor and outdoor location

Technical Specification SPE CI F I CAT I ON Clean Water Output/Hour

30-40 litres/hour

System Size

(w x l x h) 1150mm x 1300mm x 2100mm

Maximum Load Weight

650 kg

Power Supply

400V 3-phase + Earth

Average Electrical

24 kw

Consumption Services Required

FL UID PARTNER SH IPS M AKI N G A WO RLD O F D I F F E RE N CE

Power supply & compressed air

H OUG H TON IN T E R NAT ION A L

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

A P P L I C AT I O N TEC HNITEC CA HNI L A PPL CA LI CATI A PPLOINCATION

TE CHN ICAL APPL ICATION

TECHNICAL TRAINING GUIDE

F L U I D E N GI N E ER S

FL UID FLUID ENGINEER ENGINEE S TR ARISN ITNRGAIGNUIINDE G G U I DE

METAL CUTTING What is metal cutting? \\

The removal of a ‘chip’ of metal by the action of a cutting tool on a blank of material to acquire the correct geometric profile

One of the simplest methods is turning

Metal Cutting and Chip formation \\

HOT

All Metal cutting operations involve the formation of a

TOOL

chip (or swarf), generated ahead of the cutting tool \\

Metal can be pressure welded to the tool (BUE)

This effects the surface finish, tool wear and power

TOOL

consumption \\

May be reduced by altering the rake angle or cut depth or by the correct application of cutting fluid

BUILT UP EDGE (B.U.E)

TOOL

Primary functions of a MWF \\

Minimise HSE risks.

Be acceptable to operators

Prevent formation of B.U.E.

Lubricate.

Cool.

Flush away swarf and debris.

Inhibit corrosion.

Improve machine performance.

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

METALWORKING FLUID TYPES

Neat Cutting Oils

Water Soluble Coolants

Straight

Conventional

Compounded

Semi-Synthetic

Extreme Pressure

Synthetic

COOLING:

LUBRICATION:

FACTORS AFFECTING NEAT CUTTING OIL PERFORMANCE \\

Viscosity

Formulation

Contaminants

FL UID ENGINEER S TR A I N I N G G U I DE

TEC HNI CA L A PPL I CATI O N

FACTORS AFFECTING NEAT CUTTING OIL PERFORMANCE VISCOSITY Normal range for NCOs is from 5 to 40 centistokes (cSt, ISO classification) \\

Water = 1cSt

Hydraulic oil = 32cSt

But viscosity changes with temperature, the higher the temperature the thinner the oil

Advantage of low viscosity:

Advantage of high viscosity:

Less drag out on swarf

Less oil mist

Cleaner parts and machines

Less evaporation of oil

Faster filtration

Better lubrication film at higher temperatures

Easier pumping

Less aggressive to skin

Better cooling

COMPOSITION \\

Base Oils

Lubricity additives

BASE OIL TYPE \\

––

Solvent refined

––

Esters

––

White oils

––

EP (extreme pressure) additives

––

Hydrocracked oils

––

Antiwear additives

Miscellaneous additives

Mineral oils

HOUGHTON I N T E R N AT IO N A L

Synthetic oils ––

Polyalpholefins

––

Synthetic esters

The base oil can influence ––

Evaporation rate

––

Flash point

––

Misting/aerosol formation

––

Lubricity

––

Solubility of additives

––

Price

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

LUBRICITY AND EP ADDITIVES Metalworking lubricants use boundary lubricants to reduce cutting forces \\

Boundary lubricants react with the metal surfaces to form a low shear metal-additive layer

Frictional forces between metal and tool are reduced

Fatty additives, EP additives and anti-wear additives all play a part in boundary lubrication \\

They work at different temperatures

OIL + ADDITIVES Low Shear Boundary Layer

METAL-ADDITIVE BOUNDARY LAYER METAL SURFACE

Each additive has activity based on workpiece temperature. Additives can be blended to get the widest activity range

Operating or Activation Temperature Range Esters Synthetic Esters Chlorinated Paraffins Phosphorised Additives Sulphurised Additives Sulphur 0

200

400

600

800

1000

1200

Temperature (OC)

FL UID ENGINEER S TR A I N I N G G U I DE

TEC HNI CA L A PPL I CATI O N

FACTORS AFFECTING NEAT CUTTING OIL PERFORMANCE TRAMP OILS

OXIDATION

Dilute lubricity additives

Caused by heat or ageing

Increase viscosity

Acidic by-products cause corrosion of machines

Increase drag out on swarf

Sludge formation

Reduce tool life and surface finish

Lacquer formation

Solutions:

Prevent leaks!

Replace ageing oil

Critical machines can be monitored for viscosity and

Possible additions of antioxidant

Reduce sources of aeration

additives \\

Consider a dual-purpose cutting oil/lubricant

OXIDATION IS A CHEMICAL BREAKDOWN OF THE OIL, OFTEN CAUSED BY TOO HIGH CUTTING TEMPERATURES, INSUFFICIENT SUMP VOLUMES OR POOR FLUID MAINTENANCE

WATER INGRESS \\

Caused by carry-over, leaks, or condensation

Mist and fume

Machine corrosion

Solutions:

DIRT & FINES

Replace contaminated oil

Launder oil to remove water

Poor surface finish

Locate and eliminate source of water

Poor tool and wheel-life

Blockages

Skin irritation

A NEAT OIL IS EFFECTIVELY RUINED ONCE WATER HAS CONTAMINATED A SYSTEM. CORROSION AND ADDITIVE PRECIPITATION CAN OCCUR.

HOUGHTON I N T E R N AT IO N A L

Solutions: \\

Clean out system

Improve filtration

Launder oil regularly to remove fines

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

THE MAIN FUNCTIONS OF A WATER BASED COOLANT \\

Cooling of tool and workpiece: Water is 10 times better at heat transport than a neat oil

Lubrication for surface finish and tool life: Water has no lubricity properties so it needs additives

Swarf flushing: Keeps machines clean and free from dirt and swarf

Corrosion inhibition: Protection of machines and components

WHAT IS A COOLANT CONCENTRATE?

Lubricity Additives

Emulsifiers

Bio-protection

Rust Inhibitors Coupling Agents

FL UID ENGINEER S TR A I N I N G G U I DE

Mineral oil

Esters, vegetable and synthetic

Extreme pressure/antiwear additives

Glycol based polymers

Fatty acid soaps

Surface active agents

Boric acid

Biocides

Amines

Carboxylic acid amine salts

Fatty amides

Water

Glycols

MIX WITH WATER

TEC HNI CA L A PPL I CATI O N

MAIN COOLANT TYPES CONVENTIONAL EMULSIONS \\

Older technology

Milky appearance with high oil/ester content (60%+)

Protected only by a biocide

SEMI-SYNTHETIC MICRO EMULSIONS

BIO STABLE COOLANTS \\

Protects against bacteria without relying on biocides

SYNTHETIC COOLANTS

Low oil content (5-30%)

Mineral oil free

Translucent appearance

Completely soluble in water

Eg Boron amines

Can use water soluble polymers to provide lubricity

WHAT IS A COOLANT EMULSION? \\

An emulsion coolant is not soluble in water - it is a very fine dispersion of oil droplets in water

The size of the droplet determines the appearance of the emulsion

––

Large droplet give a milky opaque appearance

––

Small droplets give a transparent appearance (micro fine)

HOUGHTON I N T E R N AT IO N A L

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

FACTORS AFFECTING PERFORMANCE OF FLUIDS THERE ARE 4 MAIN FACTORS AFFECTING PERFORMANCE AND CONDITION: \\

Contamination: Tramp oil and fines

Microbiological contamination: Bacteria and fungi

Water quality: Water salt concentration

People: How fluids are managed...or not!

THE EFFECTS OF TRAMP OIL Tramp oil acts in two ways: \\

It becomes partially emulsified in the coolant

It acts as a solvent to separate oil and oily additives from water phase

Seperated Tramp Oil Layer

FL UID ENGINEER S TR A I N I N G G U I DE

TEC HNI CA L A PPL I CATI O N

THE EFFECTS OF TRAMP OIL HSE KEY POINT: TRAMP OIL LEVELS SHOULD BE <2% < 1%

Cooling tool-work interface

Excellent

Good

Moderate

Poor

Very Poor

Reduce Friction

Excellent

Good

Moderate

Poor

Flush Chips (wetting)

Excellent

Good

Moderate

Very Poor

Tool life

Excellent

Good

Moderate

Poor

Very Poor

Surface Quality

Excellent

Good

Moderate

Poor

Heavy

Misting

None

Light

Visible

Heavy

Burning

None

Light

Visible

Heavy

Bio-growth

Low*

Low

Moderate

Heavy

Foaming

Low

Moderate

Heavy

Dirt suspension

Low

Moderate

High

WATER WATER ADDITIVES OIL

HOUGHTON I N T E R N AT IO N A L

EMULSIFIER

TRAMP OIL OIL

FL U ID PA R T N E R S H IP S T H AT M A K E A WOR L D OF DIFF ER EN C E

The most important issue is: \\

AIR QUALITY DECREASES AND HEALTH RISKS INCREASE!

The solution: \\

Stop the leaks!

Remove tramp oil from the sump before it can cause damage

Other effects include: \\

Reduced tool life as tool overheats