hazards of grinding - safework sa

Hazards of Grinding

PORT ADELAIDE TRAINING AND DEVELOPMENT

CENTRE

Acknowledgments:

This occupational health and safety training resource kit was developed by Sean Boyle and Sharon Kelsey from the OH&S Management and Development Centre.

Funding for the project was provided by WorkCover to the Port Adelaide Training and Development Centre to develop Health and Safety Strategies for the Engineering and Metal Fabrication Industries.

Thanks are also due to the following individuals and organisations who assisted with the development of this OH&S training resource kit:

• Louise Sherman: Course Development Assistant, Port Adelaide Training and Development Centre.

The Project Industry Reference Group:

• Bob Oglanby, B&W Consultancy Services; Bob Hillier, Bundy Australia;

• Doug Searle, B&R Enclosures; • John Slattery, S.A. Ships; a Dennis Beck, Boss Personnel. • Lawrence Stead, Ariki Eltrak Engineering; • Margaret Johnston, Jay Ben Australia; • Peter Moore, Peter Moore Engineering.

Management &Training Staff, Port Adelaide Training and Development Centre:

• Pat O'Reilly; • Glenn Porter; • Allan Lohmeyer; • Chris Remilton; • Gary Brookes; • Randall Wilson; • Roger Bouwhuis; • Sam Mezzino; and • Peter Mack.

Introduction

This OH&S training kit is one of a number of OH&S training resources developed using a hazard management approach to assist improvements in OH&S in the Engineering and Metal Fabrication Industries.

Each training kit relates to specific hazards and OH&S management systems in the above industries:

* Welding;

* Noise;

* Manual Handling;

* Grinding;

* Aluminium Power Tools;

* OH&S Consultative Structures for Small Business; and

* Using OH&S Legislation to develop an OH&S management system.

These kits also include OH&S competencies that articulate with OH&S competencies required by the National Occupational Health and Safety Commission (Worksafe Australia) and The National Metals and Engineering Competency Standards Unit.

i'l tes & Overheads \

Learning outcome 1: At the successful completion of this session the learner

will be able to demonstrate the application of hazard management principles to different types of grinding operations in the workplace.

Assessment criteria: 1.1. identify the hazards relating to different types of grinding operations;

1.2. identify the risks relating to different types of grinding operations;

1.3. outline the methods used to assess risks related to grinding;

1.4. list some of the controls available to eliminate or reduce risks from grinding hazards;

1.5. implement controls to eliminate or reduce risks from specific types of hazards related to griding operations;

1.6. list and demonstrate the safety procedures that must be followed before carrying out a grinding operation;

1.7. list and demonstrate the safety procedures that must be followed during a grinding operation:

1.8. list and demonstrate the safety procedures that must be followed before carrying out a grinding operation;

Conditions: practical exercises and access to class notes and grinding equipment

Assessment method: written test and practical exercises

Content: information and practical exercises explaining: • hazards and risks relating to particular types of

grinding operations; • methods available to identify and assess risks from

grinding operations; • control measures to eliminate and reduce risks from

grinding operations; and • safety procedures to be implemented before, during

and after grinding operations.

Time allocated: 3 hours

Specific Competencies:, the successful completion of is-tramin course the earner .:.ciiill .be,able,to derponstrate.the,fapiilicationof az. ar 'management principleS,p,:r.different,ty1es o nnam ,operationsinthe workplace

p,riekic Competencies: At the successful ,qopipiptiolyofthi§ training course the earnetwill be 'able,t

identify the objectives Of e Occukationalilealth an Sal'etv and Well'are.Act

• outline,the , dnties of employers and employees;

• PuOjhe the*chities,o owners of lari

. idehtify the basicprinciples o hazard management

• outlinethe-role of The employer in the hazar • anagementproces

Grinding Operations

Hand held grinders Session Plan

Time Topic Reference

5 mins • Introduction and Welcome OHT 1. (Title page)

1 mins • Acknowledge WorkCover's role in providing financial support

OHT 2. (Acknowledgments)

4 mins • provide an overview of session Refer class notes

OHT 3 (Specific competency) OHT 4 (Generic competencies)

• Explain learning outcomes OHT 5 (Learning outcomes)

Learning Outcome 1

2 mins Ask group to define what "grinding" is. Whiteboard

3 mins Ask group if grinding is an occupational health and safety issue. Is it covered by the Occupational Health Safety and OHS&W Act (1986) Welfare Act (S.A.) 1986? What is the intent of the Act?

15 mins Ask group what are the responsibilities of employers and employees in relation to Whiteboard occupational health and safety (OH&S)? OHS&W Act (1986)

10 mins Outline the hazard management process; Whiteboard

10 mins Outline the role of employers and employees relating to the hazard OHS&W Regulations

management process relating to electric OHT 6 (Consultation)

hand held grinding power tools. OHT 7 (Hazard Management) OHT 8 (Other duties)

Hazard identification: OHT 9 (Employee's duties)

5 mins Ask group to define the terms hazard and risk. Provide a definition for hazard and risk

OHT 10 & 11

15 mins Divide group into small groups ask them to list hazards associated with hand held grinders.

Butcher paper

20 mins Lists main hazards related to hand held grinders and refer to hazards identified by groups.

10 mins Explain how these hazards are identified in the workplace.

._

Time

Topic

30 mins

Outline Risks to health & safety from electric hand held grinders.

20 mins

Explain risk assessment process

20 mins Using risk table ask group to carry out a

risk assessment using risks relating to a particular grinding power tool.

20 mins Explain hierarchy of controls, provide

examples of controls relating to Electric hand held grinders.

30 mins

Assessment: Short written test

Close

Acknowledgments

The Port Adelaide Training and Development Centre gratefully acknowledges the financial contribution of the WorkCover Corporation in making this training kit possible.

Cornpetencies

• identify the hazards associated with different types of grinding operations.

• outline how the risks of grinding operations can be assessed;

Employer's Duties...

Consultation .3.1.(1)

Consult with... :

• HSR,

• Health and Safety Committee;

• employees carrying out task; and

• invite registered associations where requested

Employer's Duties...

Hazard Mana ement 1.3.2. and 1a';;3

• Hazard Identification;

• Risk Assessment; and

• based on assessment of risk,

Risk Control

Competencies cont...

• identify appropriate risk control measures relating to grinding operations; and

• outline safety procedures before, during and after grinding operations.

Other Employer Duties

• information, instructio training;

• induction to new work;

• supervision; and

• employer action on report.

Employee's Duties

if employee becomes aware of hazardous situation...

• takes reasonable steps to protect themselves and/or any person(s) who may be at risk; and

• immediately report matter to employer and HSR.

A Hazard is something that has the potential to cause injury/disease to people at work.

Hazard

Risk

Risk is the likelihood

that a hazard will cause

injury or disease in the

workplace for example:

• the way a hazard is used or occurs in the workplace; and

• the severity of injury disease.

Identification of Health & Safety Hazards

• Consultaion

• Hazard inspections.

• Injury records/reports.

• Other information sources.

Hazards of grinding.

• Noise

• Airborne particles

• Moving parts of

hand held grinders

• Electricity

—* high tones low tones 4-

1,0

0,8

0,6

0,4

0,2 thickness of one sound absorbant mounted directly against the wall 10 5 2,5 1 cm

absorption factor (indicates the portion of the incoming sound which is controlled) 1

SOUND MOVEMENT INDOORS • ABSORPTION

Thick, porouc layers absorb both high and low frequency sound Porous material through which air can be pressed often makes a good sound absorbant. Examples of such materials include felt, foam rubber, foamed plastic, textile fibers and a number of sintered metals and ceramic materials. If the pores are closed, the absorption

Principle

is slight. Thin porous absorbants handle high tones. For good effects below 100Hz, the thicknesses required may become impractical. Low frequency absorption is improved with the aid of an air gap behind the absorbant.

Example A workshop with intense low frequency noise is provided with absorbants that are effective for low tones. One part of the shop contains space for hanging absorp-tion baffles, which provide good low frequency absorption and are easily in-

stalled. A traverse leaves no room for baffles in the other part of the shop. Instead, horizontal absorbant panels are installed above the traverse, 8 inches from the ceiling, to improve the low frequency absorption.

fine-meshed wire gauze

meshed wire gauze

a porous sound-absorbing material

noise-producing turbulence

mixing area

f*

mixing area

gas flow

—

MII01111+

Turbulence becomes more violent in the already dis-turbed stream

impediment

Example The exhaust air from a compressed air-driven grinding machine produces a loud noise. The air becomes turbulent while leaving the machine through the side handle.

Control measure A new handle is developed, filled with a porous sound-absorbing material between two fine-meshed gauzes. Passage through the porous materials breaks up the turbulence. The air stream leaving the handle is less disturbed, and the exhaust noise is weaker. A straight lined duct-type muffler may also be used.

sound-damping handle

compreSsed air-driven grinding' machine

1 compressed air

SOUND PRODUCTION IN AIR OR GASES • DUCTS

Undisturbed flow produces the smallest amount of exit noise When a flowing gas mixes with a non-moving For speeds below 325 feet/sec., reduction of the gas, noise may be produced, especially if the speed by half will mean that the sound will be flow is disturbed before the outlet. A lower about 15 dB weaker. outflow speed will produce a lower sound level.

Principle

Airborne particles

Grinding dust:

• can be generated from the metal a person is grinding or the grinding disc:

• Some metal dusts for example aluminium, copper, are toxic and dust from grinding discs can easily penetrate the lungs causing short and long term damage.

Airborne particles

Grinding dust:

• can irritate your nose, throat, and upper airway.

• Some particles, depending on their size and type, can pass through to the lungs, damage lung tissue and cause serious health effects.

Airborne particles

Grinding dust particles • invisible to the human eye

can penetrate deep into the lungs and may cause chronic health problems, scaring of the lung tissues (pulmonary fibrosis)

• This scaring reduces the lungs ability to transfer oxygen.

Table 1: Risk Probability (Likelihood)

Very Likely Exposure to hazard likely to occur frequently

Likely Exposure to hazard likely to occur but not frequently

Unlikely Exposure to hazard unlikely to occur

Highly Unlikely

Exposure to hazard so unlikely that it can be assumed that It will not happen

Table 2: Risk Severity & Consequences

Catastrophe Hazard may cause death or total loss of one or more bodily functions (e.g. loss of use of arm, leg or sight). Greater than 4 months off work.

Critical Hazard may cause severe injury, permanent partial loss of one or more bodily functions (e.g noise induced hearing loss, severe illness) or major property damage. 2 weeks -4 months away from work.

Major Hazard may cause a "reportable" accident i.e. an accident that result in the employee being unable to undertake their normal duties for 5 days or more or significant property damage.

Minor Hazard may cause minor injury (1-5 days lost), illness or property damage.

Negligible Hazard has very little effect on employee safety or health; a first aid only accident with less than 30 minutes loss of work

Table 3: Risk Assessment

Probability Rating Catastrophic Critical Major Minor Negligible

Very Likely 1 1 2 3 3

Likely 1 2 3 4 4

Unlikely 2 - 3 4 4 4

Highly Unlikely 3 3 4 5 5

Table 4: Risk Rating Priority

1 Urgent

2 High

3 Medium

4 Low

5 None

Risk Assessment Table(s) WorkCover

1:1TA CSCON1C1 1111S‘CYrEAP.WPD- 21/4197

WorkCover AptIl 1997

Control Hierarchy Can the hazard be ELIMINATED by design & engineering?

No

Can the hazard be removed by SUBSTITUTION?

No Can the risk be reduced by ENGINEERING (isolation,

barriers, extraction, mechnaisation)?

No' Can the risk be reduced by ADMINISTRATIVE CONTROLS

(training, supervision, safe operating procedures.....)?

No

Can PERSONAL PROTECTIVE EQUIPMENT be used to reduce the risk?

Remember that PPE requires administrative support ie. training...

Risks from Grinding

Portable Grinding Power Tools • Hand held grinders are one of

the most dangerous tools in the metal fabrication industry.

• Kick back where the disc is thrust away from the object it is grinding, can result in severe cuts to hands, arms, head torso or legs.

• Discs can shatter or explode, sending pieces flying.

• Most grinding injuries are from metal particles in eye.





Highly Unlikely




Critical Hazard may cause severe injury, permanent partial loss of one or more bodily functions (e.g noise induced hearing loss, severe illness) or major property damage. 2 weeks - 4 months away from work.







Likely 1 2 3 4 4

Unlikely 2 3 4 4 4



1 Urgent

2 High

3 Medium

4 Low

5 None

Risk Assessment Table(s) WorkCover giutagainizigan

MTACSCOMCHRISNCYY\EAP.WPD- 21/4/97

0 WolkCover April 1997


No




No Can the risk be reduced by ADMINISTRATIVE CONTROLS


No



Controls

Elimination:

• Is grinding needed can another process or tool be used with less risk?

Portable Grinding Power Tools Control of moving parts

Engineering: • Ensure guards cover

half the disc between operator and the disc.

• Use hand held grinders with built in clutch, this stops the disc turning if caught in workpiece.

(Noise) • hand held grinders are not noisy it is

the surface or material they are grinding with the disc that generates the noise.

• On average 114 dB(A), using a four inch angle grinder on a steel hull of a ship;

• Max. exposure time to noise at this level is 1 min. 50 secs. (8hrs).

• Noise level from larger grinders approx. 120dB(A), max. exposure time to this noise level is 28 seconds.

Risk Assessment Table(s) W orkC over MELLICIEWSEI





Highly Unlikely




Critical Hazard may cause severe injury, permanent partial loss of one or more bodily functions (e.g noise induced hearing loss, severe illness) or major property damage. 2 weeks - 4 months away from work.







Likely 1 2 3 4 4




1 Urgent

2 High

3 Medium

4 Low

5 None

IATACSCON1CIMISCYYNEAP.WPD- 21/4/97

WorkCover April 1997




No

Can the risk be reduced by ADMINISTRATIVE CONTROLS (training, supervision, safe operating procedures.....)?




No'

No

Airborne Particles Controls

Elimination:

• Is grinding needed can another process or tool be used with less risk?

t TECXHAUST SYSTEM

Filter (Cartridge)

WINDPIPE

Airborne Particles Controls

Engineering & PPE:

Local Exhaust ventilation:

• Helps extract most small grinding particles directly from the work area,

• However to ensure further protection against inhalation of dust particles identified as hazardous use disposable, half face respirator or full - face filter (cartridge) respirator. HALF-FACE TO LUNGS

FILTER (CARTRIDGE) RESPIRATOR

Controls against the risk of electrocution during grinding (Administrative)

• Safe work procedures should be written and implemented for every type of grinding operation in the workplace.

• These should be developed in consultation between the employer, their employees and if requested employee representatives.

Electric Shock

There is a serious risk for electric shock when using hand held electric grinders the main hazards include:

• poorly maintained & damaged electrical equip.;

• earth leakage devices not being used;

• electrical cord from grinder laying in water;

• grinder accidentally cutting through electrical leads.

Factors affecting the Severity of Electric Shock

• Magnitude or level of the voltage entering the victims body.

• Type of current.

• Resistance of the body and any insulation to the electric circuit.

Level of resistance

• Resistance to electric shock depends on the:

• paths of the current;

• touch voltage;

• current flow duration;

• frequency;

• moisture on skin;

• insulation/protective clothing; and

Electrocution

The main cause of death

from electrocution is

ventricular fibrillation

( a form of heart failure).

The minimum amount

of current causing

ventricular fibrillation

depends on the current

path, duration & a persons

health.





highly Unlikely




Critical Hazard may cause severe injury, permanent partial loss of one or more bodily functions (e.g noise induced hearing loss, severe illness) or major poverty damage. 2 weeks - 4 months away from work.







Likely 1 2 3 4 4




1 Urgent

2 High

3 Medium

4 Low

5 None

Risk Assessment Table(s) W orkCover i=1

MTACSCOPACIMISNCYYTAIP.WPD- 2114/97

WorIcCover Aprll 1997


No




No ' Can the risk be reduced by ADMINISTRATIVE CONTROLS


No



compressed air-driven grinding machine

Controls for risks from electric shock

Elimination/Substitution:

• The risk of electric shock from hand held power tools for grinding can be eliminated by using air operated tools.

• If this is not possible other controls need to be used:

engineering, administrative, and PPE compressed

air

Double pole Circuit Breaker

Earth leaka1ge

core - balance relay inside case

,•• ..•••• I •=.: k.)

n • • • r) t;

171= I!


Engineering:

• Earth Leakage Devices must be used when using electric power tools for grinding.

• These devices cut of the electricity supply and significantly reduce the level of electric shock received by the operator using the grinding tool.

Self - switching power outlets

Unwind reels complete!y during use N

,••••••

! <07 •

••••


Engineering & Admin:

• Use electrical extension leads 15 A and above with hand held grinding power tools.

• Use extension leads that are as short as possible (long extension leads expose user to a greater risk of electric shock).

• Completely unwind extension lead reels.

Extension lead

HeF.vy timber

H:r-CUI3 PS'S U3S WSATAS*?..C.t2CS

Controls for risks form electric shock

Engineering & Admin:

• Use stands to keep electric extension leads of the ground;

• Protect leads that cross traffic areas;

• If possible suspend leads overhead at a safe height;

• Remove leads from sockets and roll up when not in use.

Controls against electrocution for grinding (Administrative)

• A risk assessment must be carried out for all hand held grinders and other plant in accordance with OHS Regulations under the OHS&W Act (1986).

• This should include consultation between the employer and employee health and safety representative.

Controls for risk from electric shock

Administrative:

• All earth leakage devices and other electrical equip. used in the workplace (grinders, extension leads) must be tested, tagged and repaired by a licensed electrician.

• Tags show electricians certificate of competency number & when next test is due.

hazards of grinding - safework sa

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