Machinery And Equipment Safety – An Introduction

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WorkSafemachinery and equipment safety– an introduction1ST EDITIONWorkSafeInfoline 1300 307 877(for the cost of a local call statewide)Westcentre 1260 Hay Street West Perth Western Australia 6005PO Box 294 West Perth Western Australia 6872Administration: (08) 9327 8777Facsimile: (08) 9321 8973National Relay Service: 13 36 .wa.gov.auRegional officesGoldfields/EsperanceGreat SouthernKimberleyMid-WestNorth-WestSouth-West(08) 9021 5966(08) 9842 8366(08) 9169 2811(08) 9964 5644(08) 9185 0900(08) 9722 2888DP1979/2007/1- January 2008 - 2000This publication is available in other formats to assist people with special needs.

CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. Key principles of machinery andequipment safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 Mechanical hazards. . . . . . . . . . . . . . . . . . . . . . . 31.2 Non-mechanical hazards. . . . . . . . . . . . . . . . . . . 41.3 Access hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 52. Risk control of machinery andequipment hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1 Risk control of machinery and equipmenthazards (general) . . . . . . . . . . . . . . . . . . . . . . . . 82.2 Risk control of mechanical hazards. . . . . . . . . . . 92.3 Risk control of non-mechanical hazards. . . . . . 132.4 Risk control of access hazards. . . . . . . . . . . . . 143. Purchasing machinery and equipment list. . . . . . . . 184. Information and guidance: Where to getmore information and assistance. . . . . . . . . . . . . . . 20AcknowledgementWorkSafe Western Australia acknowledges WorkSafe Victoria for the original development of this publication.DisclaimerInformation in this publication is provided to assist people in meeting their occupational safety and health obligations. While information iscorrect at the time of printing, readers should check and verify any legislation referenced in this publication to ensure it is correct at the timeof use.Changes in law after this document is published may impact upon the accuracy of information. This information is provided as a service tothe community. It is made available in good faith and is derived from sources believed to be reliable and accurate at the time of publication.

IntroductionMachinery and Equipment Safety: An Introduction is provided in accordance withthe Occupational Safety and Health Act 1984 (OHS Act) to assist employers andemployees comply with their duties and obligations.This guide is an introduction to managing the risks associated with use ofmachinery and equipment in the workplace.Employers can use this guide to: identify machinery and equipment hazards in the workplace eliminate or reduce the risk of those hazards causing harm.The guide will also be useful to anyone else who is interested in machinery andequipment safety, such as employees and Safety and Health Representatives.WorkSafe also has additional guidance supporting all topics introduced in thisdocument. To find out more or to seek further technical information with regardto your machinery and equipment, refer to Section 4 of this document.Consulting employees and Safety AND HEALTHRepresentativesConsultative processes allow people to provide input and raise potential safetyconcerns about the work they undertake. Although hazards associated withmachinery and equipment are often easily identified, the ways in whichpeople can gain access to, or may be exposed to, hazards require a detailedunderstanding of how they do their job.MACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION 1

1Key principles ofmachinery andequipment safetyRisks associated with:1.1 Mechanical hazardst hat cannot be eliminated must becontrolled to prevent harm.1.2 Non-mechanical hazardst hat cannot be eliminated must becontrolled to prevent harmful exposure.1.3 Access hazards2t hat cannot be eliminated must becontrolled to provide safe access(for operation, maintenance, repair,installation, service, cleaning ordecommissioning).MACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION

Key principles of machineryand equipment safety1.1 Mechanical hazardsMachines have moving parts. The action of moving parts may have sufficient forcein motion to cause injury to people.When reviewing machinery and equipment for possible mechanical hazards,consider: machinery and equipment with moving parts that can be reached by people machinery and equipment that can eject objects (parts, components, productsor waste items) that may strike a person with sufficient force to cause harm machinery and equipment with moving parts that can reach people such asbooms or mechanical appendages (arms) mobile machinery and equipment, such as forklifts, pallet jacks, earth movingequipment, operated in areas where people may gain access.Robotic arms can reach over their base, movewith remarkable speed and high force, andcan cause injury if controls to separate peoplefrom moving plant are not implemented.Common mechanical hazards and associated risks for machinery and equipmentare shown below.Mobile plant operated in areas where peoplework may cause injury through collision. Trafficcontrol and segregation are forms of control.hazardRiskRotating shafts, pullies, sprockets and gearsEntanglementHard surfaces moving togetherCrushingScissor or shear actionSeveringSharp edge – moving or stationaryCutting or puncturingCable or hose connectionsSlips, trips and falls (e.g. oil leaks)Further InformationCommission for Occupational Safety and Health guidance notes: Plant in the workplace Powered mobile plant Safe movement of vehicles at workplaces Working safely with forkliftsMACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION 3

Key principles of machineryand equipment safety1.2 Non-mechanical hazardsNon-mechanical hazards associated with machinery and equipment can includeharmful emissions, contained fluids or gas under pressure, chemicals and chemicalby-products, electricity and noise, all of which can cause serious injury if notadequately controlled. In some cases, people exposed to these hazards maynot show signs of injury or illness for years. Where people are at risk of injurydue to harmful emissions from machinery and equipment, the emissions should becontrolled at their source.When reviewing machinery and equipment for possible non-mechanicalhazards, consider how machines and equipment can affect the area(environment) around them.Common non-mechanical hazards are shown below.Woodworking dust generated by a buzzer isremoved via forced extraction and ventilation.Non-mechanical hazardsDustMist (vapours or fumes)Explosive or flammable atmospheresNoiseHeat (radiated or conducted)Ignition sources (flame or spark)High intensity light (laser, ultra-violet)Molten materialsHeavy metals (lead, cadmium, mercury)ChemicalsSteamPressurised fluids and gasesIonising radiation (x-rays, microwaves)ElectricalWelding fumes are extracted via flexible,locatable forced extraction and ventilation system.Further InformationCommission for Occupational Safety and Health codes of practice: Managing noise at workplaces Spray paintingCommission for Occupational Safety and Health guidance notes: Controlling wood dust hazards Controlling Isocyanate hazards at work Prevention of carbon monoxide poisoning from petrol and gas poweredequipment Material safety data sheets4MACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION

Key principles of machineryand equipment safety1.3 Access hazardsPeople must be provided with safe access that is suitable for the work they performin, on and around machinery and equipment. A stable work platform suited to thenature of the work that allows for good posture relative to the work performed, surefooting, safe environment and fall prevention (if a fall may occur) is a basicrequirement.As an example, cooling towers on building roofs may have poor access, yet mustbe attended by a service person at predictable times for water treatment, chemicaldosing or monitoring of automated dosing equipment. People performing thesetasks must be provided with the means to get themselves and any equipment theyrequire onto the roof with no risk or minimal risk of fall or injury.When thinking about safe access to machinery and equipment, think about how,who, when and what: who will be working on or around the machinery and equipment? people required to work in enclosed areas where the atmosphere couldbe harmful, such as pits, tanks or storage vessels? what equipment or materials need to be carried to undertake the task? where and when is access required for operation, maintenance and cleaning? how will people gain safe access (walkway, gantry, elevated work platformor ladder)? what work will be carried out during access? will people be near or exposed to an unidentified mechanical ornon-mechanical hazard at the time of access? has consultation occurred with employees or contractors regarding how theyintend to gain access, and what equipment and work platform or structure isbest suited for the intended task?Permanently fixed gantries, ladders andwalkways are incorporated into this machineryand equipment to reduce the risk of a fall fromheight occurring during operationand maintenance.AccessAccess needs can be predicted and access planning must occur in advance.People need access to machinery and equipment in the workplace (either continuallyor occasionally) for tasks such as operation, maintenance, repair, installation,service or cleaning. These tasks are examples of access that can be predicted.Access may vary during each stage of machinery and equipment life cycle.For example: installation or removal– complete access from every area may be required, and involvedisconnection or connection of services such water, air, pipes,installation of electrical cable to switch board, etc. operation– access for set-up, operation and adjustment. maintenance, repair, cleaning, alteration or adaptation– access to remote areas may be required.Further InformationCommission for Occupational Safety and Health code of practice: Prevention of falls at workplacesCommission for Occupational Safety and Health guidance note: Working aloneMACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION 5

Key principles of machineryand equipment safetyExamples of common hazards by type of workplace activityPeople who install or dismantle machines and equipment could: work in isolation work on machines and equipment at height or over machinery or equipment to connect services (such as electricity, air or water) work in low light or with bright directional light access machinery and equipment from the top, sides or underneath work with/near cranes, forklift or rigging to lift machinery and equipment work in confined spaces use power tools, welders, extension leads, which present electrical hazards if damaged or wet.People operating machines and equipment could: b e required to place their hands close to the mechanism of the machinery or equipment that does the work, and may be injuredif caught or trapped by moving parts b e exposed to constant harmful noise, radiated energy or fumes being emitted from the machinery and equipment they are operatingor are close to inadvertently bump or knock poorly placed control levers or buttons be required to make adjustments to the mechanism of machinery and equipment while the machine is in motion be required to clear away scrap make minor adjustments or reach into the moving mechanism of the machine they are operating.People providing maintenance or repair services could: work alone work on machines and equipment at height, or over machines and equipment to connect services (such as electricity, air or water) access machines and equipment from the rear or sides need to enter confined spaces of larger machinery and equipment b e trapped by mechanism of the machinery and equipment through poor isolation of energy sources or stored energy, such asspring-loaded or counter-balance mechanisms, compressed air or fluids, or parts held in position by hydraulics or pneumatic (air) rams m ove heavy parts when changing the set-up of machinery and equipment, or repairing failed parts such as electric motorsor gear box assemblies disable or remove normal safety systems to access machines and equipment mechanism.People providing cleaning services could: work alone access machines and equipment from the rear or sides or in unexpected ways climb on machines and equipment enter confined spaces of larger machines and equipment b ecome trapped by mechanism of the machinery and equipment through poor isolation of energy sources or stored energy, such asspring-loaded or counter-balance mechanisms, compressed air or fluids, or parts held in position by hydraulics or pneumatic (air) rams work with chemicals operate electrical equipment in wet areas.6MACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION

2Risk control ofmachinery andequipment hazards2.1 R isk control of machinery andequipment hazards (general)2.2 Risk control of mechanical hazards2.3 Risk control of non-mechanical hazards2.4 Risk control of access hazardsMACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION 7

Risk control of machineryand equipment hazards2.1 Risk control of machinery and equipmenthazards (general)Where exposure to machinery and equipment hazards cannot be eliminated orsubstituted for machinery and equipment of improved design, risk control(s) mustbe applied to the hazards that prevents or reduces the risk (chance) of injury orharm. Health and safety laws require the highest order control be applied so faras is reasonably practicable.Centre lathe: The exposed rotating chuckof a centre lathe can eject parts or tools withgreat force, cutting fluid fumes are difficultto contain and the machinery requiresmanual set-up.Higher order machinery and equipment risk controls are preventative by nature,are effective and durable for the environment it is used in, and deal directly withthe hazard at its source.Lower order machinery and equipment risk controls, such as personal protectiveequipment (PPE), can prevent injuries, but are generally not as effective as higherorder controls, as they rely more on employee behaviour, maintenance programsand supervision.Administrative controls use systems of work to reduce risk by providing aframework of expected behaviours. Examples are rotation of staff to reduceexposure to a hazard, or a documented safe system of work, such as ‘lockout-tag out’. These types of controls rely on extensive instruction, information,training and supervision. In terms of time and ongoing administration by managersand employers to ensure the desired behaviour occurs, administrative controls canbe the most expensive and least effective form of hazard control.CNC Lathe: Substituting a centre lathe witha CNC lathe (Computer Numeric Control) is anexample of improved risk control of machineryand equipment through improvement in design.8Note: The use of PPE and administrative controls are low or last order controlsused to deal with any residual risk associated with the hazard.As such, these last resort controls can be used in support of higher order controlsthat deal with a hazard at its source and should not be consideredas the sole means of control. These types of risk controls require constantmonitoring and reinforcement.Effective machinery and equipment risk controls reflect some or all of thefollowing characteristics: the hazard is controlled at its source contact or access to the hazard is prevented sturdy construction (correct materials with few points of potential failure) fail-safe (failure of the control system to be effective will result in machineryshut-down) tamper-proof design (as difficult as possible to bypass) presents minimum impediment to machinery and equipment operator easy to inspect and maintain does not introduce further hazards through action of the risk control.MACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION

Risk control of machineryand equipment hazards2.2 Risk control of mechanical hazardsSeparation is a simple and effective machinery and equipment risk control.Separation may be achieved by distance, barrier or time. Distance separation means a person cannot reach the hazard due to distance. Barrier separation means an effective barrier or guard denies access andcontrols ejection of parts, products or waste. Time separation means at the time of access, the machinery or equipmentis disabled.Fences, barriers, guards and interlocked gatesseparate people from the hazardous actionof machinery and equipment.Examples include: physical barriers and guards such as fences, screens or fixed panels ofvarious materials various forms of guarding and interlocking (as described in Australian StandardAS 4024, part 1601 and part 1602, Safety of Machinery) making the hazard inaccessible by reach (where the distance between a personand the hazard forms an effective barrier).Note: When considering the suitability of distance guarding, also consider the safeaccess requirements of maintenance people who gain access by ladder, scaffold orelevated work platform.GuardingA guard can perform several functions: it can deny bodily access, contain ejectedparts, tools, off-cuts or swath, prevent emissions escaping or form part of a safeworking platform.An old style power press incorporating amanual interlock and adjustable guarding.If the guard slides up, a connected metalbar separates the clutch mechanism andthe press will not activate.The guard can be adjusted to provide anopening by releasing retaining bolts on theguard face to allow individual panels to move.Adjustment must be performed by anexperienced person to ensure the resultingopening only provides room necessary toincorporate the material being fed in andprevents hands or fingers intruding into thedanger area.Guarding is commonly used with machinery and equipment to prevent access to: rotating end drums of belt conveyors moving augers of auger conveyors rotating shafts moving parts that do not require regular adjustment machine transmissions, such as pulley and belt drives,chain drives, exposed drive gears any dangerous moving parts, machines or equipment.Where access is not anticipated, a fixed guard can be permanently applied bybonding agent, welding or secured with one-way screws. If access is generallynot required, a permanently fixed barrier is the preferred option.Where access to the hazard is infrequent, the installation of a fitted guard thatcan be removed by use of a tool may be an acceptable control, where the toolto remove the barrier or guard is not normally available to the operator.Adjustable guarding incorporates movable sections or panels of the guard andallows for material or parts to be fed into the guarded area while still preventingbodily contact.MACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION 9

Risk control of machineryand equipment hazardsTunnel guards provide a tunnel, aperture or chute in which material can beinserted into the machinery and equipment, but due to the restrictive designand depth of the opening, fingers, hands, arms or the entire person is preventedfrom intruding into the danger area.Where frequent cleaning is required, the guard may be constructed of mesh thatprevents intrusion of body parts but allows for hosing. Food production workplacesthat use conveyors in areas where hygiene or food safety is an integral part of theoperation use fixed mesh guarding of conveyor end rollers.Interlock guarding occurs when the act of moving the guard (opening, slidingor removing) to allow access stops the action of the hazardous mechanism.The narrow th

MACHINERY AND EQUIPMENT SAFETY – AN INTRODUCTION 1 IntroductIon Machinery and Equipment Safety: An Introduction is provided in accordance with the Occupational Safety and Health Act 1984 (OHS Act) to assist employers and employees comply with their duties and obligations.

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