Published September 2007
Respect the Suction
By Scottie Dayton (page 38)
Proper safety procedures are a huge concern for pumping contractors who add industrial vacuum-loading services.
Increased competition or changing demographics can create the need to diversify septic pumping businesses. One direction is stepping into the industrial vacuum-loading field as a subcontractor. Jobs can include vacuuming grain or coal dust, sandblasted material from highways and bridges, debris from catch basins, and solid or liquid spills. Just think how often someone said, “Hey, you have a pump truck. Can you clean this up for me?”
Operating a septic system pumper truck and a vacuum loader is like owning a house cat and a lion. Both are felines, but that’s where the similarity ends. Matt Brenes, health and safety manager for CCS, an industrial and tank cleaning, emergency response, and sweeping business in the Pacific Northwest, says inexperienced operators tend to run into trouble when they get clothing caught or automatically reach for objects lying near the end of the hose.
In one story circulating through the industry, the hose snagged the sleeve of an operator’s rain gear as he cleaned a tank. He tried to free his stuck fingers with his other hand, which was sucked into the hose. The power of the vacuum truck dragged him and two men attempting his rescue across the tank. Every blood vessel in the worker’s arm was ruptured. Amputation wasn’t necessary, but months of physical therapy followed.
Pumper: Why is operating a vacuum loader different from running a pumper truck?
Brenes: Vacuum pumps on pumper trucks generally operate in the 76 to 425 cfm range. Industrial vacuum loaders handle materials from sluggish liquids to fine, light powers and dust, moving them at 3,000 to 6,400 cfm. Not only is the volume of air greater, but the hose diameter is larger. Pumper trucks normally have a 3-inch hose with a suction radius of 6 to 8 inches. Vacuum loaders use 8-inch hoses with a suction radius of 24 inches.
Pumper: What are some common mistakes novices make when operating a vacuum loader and why?
Brenes: One of the biggest mistakes is not respecting the power of these machines. Pumper truck operators can put their hands near the end of the hose and nothing will happen. Get anything near the end of an industrial cleaning hose and it’s up into the debris tank before anyone realizes it’s gone. Anyone who has operated pumper trucks for years and switches to an industrial loader will have to be doubly careful to respect the end of the hose and its suction radius.
If a pumper truck hose grabs the operator, he can break the seal without any harm to himself. Breaking free is impossible with a vacuum-loading hose. CCS incorporates a safety tee into every vacuum-loading hose. The device, within reach of the operator, quickly breaks the pressure and releases the suction when the handle is pulled. Safety tees are necessary because it takes 15 to 20 seconds for a vacuum loader to cycle down.
Our shop fabricates safety tees, but they are commercially available. Nobody should operate a vacuum loading truck without one. CCS has had a couple of experiences where someone almost had a leg stuck, and it did happen once. The safety man was right there to pull the safety tee handle, the pressure was released in two seconds, and the employee was uninjured.
Pumper: Is it necessary to have a safety worker watching the operator on every job?
Brenes: The policy at CCS is that vacuum operators never work alone. Period. Why run the risk? Furthermore, if an employee is hurt while in a customer’s plant, that recordable incident goes on his company’s safety record. If the safety tee is pulled during the job, due to the hose sticking to the floor or something else, in certain situations, the incident may be written up and reported as a near miss.
Pumper: As a near miss, how do you handle the safety training?
Brenes: Our standard protocol requires the employee in question to fill out an Employee Incident form, and the job foreman to fill out a Supervisor form. Those are forwarded to the Safety Department where we do a full investigation, then distribute our findings to all division managers, who hold safety meetings and present the material to the employees.
Besides monthly safety meetings in all divisions, we have daily Toolbox safety meetings before every job. Any near miss is brought up at the next day’s Toolbox meeting as a bullet item.
Pumper: Here’s a scenario: A septage pumper buys a vacuum loading truck that will generate 20 percent of the company’s income. He’s thinking, “Do I really need that safety man? It will mean hiring a part-time person.”
Brenes: The other side of the question is: How much will it cost if his vacuum-truck operator is seriously injured? The employer is looking at paying medical bills, medical leave, and possibly fines from the state. Spending money upfront on proper safety equipment can save the company a lot of money in the long run.
No one simply jumps in a truck and heads to a job. Crews first have the Toolbox safety meeting. Their supervisor then goes over the vacuum truck check-off sheet CCS developed for them to fill out before every job. They have to think about the answers, not just put checks in a column of boxes. The sheet touches on all the subjects we’ve discussed. The crew must sign the sheet, acknowledging that they are aware of this job’s particular hazards.
Pumper: What are the major safety points emphasized during your training sessions?
Brenes: Number one is operator safety. Getting the job done quickly is way down the list. Our vacuum-loading truck trainees ride for a minimum of one week with experienced operators and just watch. They learn to look for specific things, such as, is the work in a confined space or around flammable or explosive material?
Number two is learning to operate the trucks safely. That doesn’t include the Department of Transportation pre-trip inspection form that involves checking dozens of items on the truck. Making sure all the truck doors work and that the various seals aren’t cracked are two examples of items that should be checked before leaving the yard. The seller who delivers your vacuum loader should relay that information. As a buyer, always ask for a list of items to check every time before that expensive piece of equipment leaves the yard.
Pumper: If a pumper buys a vacuum loader and doesn’t have an experienced driver, what is his alternative?
Brenes: I would hope that the company selling the equipment would send a representative for a few days to show him how to use it correctly. As the buyer, I would write three or four days of training into the purchase agreement.
Pumper: Despite all the training and refresher courses, why are some vacuum-loading operators still injured or sometimes killed?
Brenes: The company probably doesn’t have the proper safe operating policies and standard operating procedures. It’s a combination of that and not having proper training or safety devices, like the safety tee. We do annual training and refresher courses for all our guys, even those who have been with us for 10 years. We never let up. That’s why we have our vacuum truck check-off sheet. Four different jobs in one day require four separate check-off forms.
Every job has different hazards. Even if crews return to the same job on two consecutive days, some aspect will be different. It’s the supervisor’s responsibility to lead the safety meeting, but it’s a democratic process where everyone is part of the discussion.
Pumper: For hiring purposes, what characteristics exemplify potential competent vacuum-loading operators?
Brenes: Responsibility and attention to detail. Experience is nice, but it can come with bad habits. I’d rather hire the individual who has those two characteristics and the ability to follow directions. The interview process will reveal some of it, but always try to confirm them by checking the applicant’s previous employer references.
Pumper: What is the most important thing readers should take away from this article?
Brenes: Vacuum-loading trucks are very efficient, but if not used correctly, they can be very dangerous.
