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IGC 2: ELEMENT 4IGC 2: ELEMENT 4

WORK EQUIPMENT WORK EQUIPMENT HAZARDS & CONTROLHAZARDS & CONTROL

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WORK EQUIPMENTWORK EQUIPMENT• "Work Equipment" is anything used to

do a job of work, including employees' own equipment;

• Hand tools e.g. screw drivers, wrenches, hammers, handsaws…etc.

• Power tools e.g. Chainsaws, Drills…etc

• Machinery e.g. photocopiers, concrete mixers, grinders, circular saws… etc

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SUITABILITY OF WORK SUITABILITY OF WORK EQUIPMENTEQUIPMENT

work equipment has to conform to some standards:

•Initial integrity

•The place where it will be used

•The purpose for which it will be used

WHAT DO BUYERS NEED WHAT DO BUYERS NEED TO CONSIDERTO CONSIDER!?!?

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SAFE USE & MAINTENANCE OF SAFE USE & MAINTENANCE OF EQUIPMENTEQUIPMENT

TRAINING, INFORMATION & INSTRUCTIONSTRAINING, INFORMATION & INSTRUCTIONS

MAINTENANCE: MAINTENANCE: planned preventive / condition based / breakdown based

• INSPECTIONINSPECTION

• EXAMINATION & TESTINGEXAMINATION & TESTING

• OPERATION CONTROLS & WORKING OPERATION CONTROLS & WORKING ENVIRONMENTENVIRONMENT

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Manufacturers & suppliers need to make sure the machinery is safe when supplied and has the CE marking. Manufacturers have to:•Assess all foreseeable risks & find out about OHS hazard likely to be present when the machinery is used.•Consider safety issues in design phase & Design the machinery free of OHS risks is possible.•Provide appropriate safe guards, use warning signs, to warn of hazards.•Fix CE marking on the machine; to show they have complied with relevant supply laws.•Provide the buyer with information & instructions to explain how to install, use & maintain the machinery safely.•Issue a Declaration of Conformity" for the machine; to show it complies with essential OHS requirements.

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Prior to purchasing new equipment, Buyers need to consider:

•What the equipment will be used for.•Where & How it will be used.•Who will use it; skilled personnel, employees…etc.•What OHS risks might come out?•How well OHS risks are controlled by manufacturers.

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Safe Use & Maintenance of Equipment with specific Risks; Hierarchy of control:•Eliminating the risks•Taking physical Engineering controls to control risks e.g. guards•Appropriate administrative controls; safe system of work•The Use, repairs, servicing or maintenance of such equipment should be restricted to designated authorized personnel who:•Received sufficient Training.•Received adequate information & familiar with work instructions.•Have enough experience & sufficient skills to carry out such tasks.

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Information, Instruction & Training; personnel (employees, workers, supervisor, managers…etc) using & maintaining work equipment need to receive sufficient information, instruction & training which at least should cover:•All OHS aspects•Limitations on the use of equipment•Any foreseeable risks & problems that could occur•Safe methods & controls to deal with such risks & problems•The complexity of equipment, the level of risks involved & the competence of the person doing the job, will al determine the amount of training required.

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Maintenance:• Has o be done by competent well trained maintenance

personnel.• A safe System of Work to be used; ensure safe environment,

proper isolation procedures, right tools & equipment for the job…etc e.g. to implement Permit To Work.

• Planned Preventive maintenance; regular scheduled maintenance to replace parts & service as appropriate in a proactive manner.

• Condition Based maintenance; monitoring the condition of critical parts & carrying out maintenance as necessary.

• Break down based maintenance; reactive & only takes place when failures occur.

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Inspection:• After installation for the first time.• After assembly at a new site or a new location.• At reasonable intervals & following incidents.• Prior to each use in high risk equipment & as a part

of the Work Permit procedures.

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Examination & Testing of pressure systems: wide range of pressure vessels & systems require thorough examination by a competent person (usually a specialist inspector from a 3rd party organization), and employers who operates steam boilers &/or pressurized hot water plant… etc, must ensure:•Equipment is supplied by correct updated written information & markings.•Properly installed.•There is a written scheme for periodic examination of equipment is certified by a competent person, a report of periodic examination with corrective actions provided & implemented.

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Statutory InspectionsEquipment Inspections of Frequency

Cranes, hoists and lifting equipment

• All equipment used for lifting people and lifting accessories

6 months

• Other lifting equipment 12 months

Pressure systems • Steam plant (boilers) 14 months• Steam receivers 26 - 38 months*

• Air receivers 24 - 48 months*

Power presses • Fixed guards 12 months

• Other guards 6 months

• Inspection of guards and protective devices during work

4 hourly

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HAND TOOLSHAND TOOLS

HAZARDS:• Misuse & poor maintenance;• Broken handles e.g. can cause a

hammer handle to fly off• Cut wounds on incorrect use of

saws, knives & chisels.• Slipping tools stab wounds• Flying particles that hit the eyes

CONTROL:• All tools to be suitable for

the purpose• Protected & isolated for

electrical use\• Good quality material

which will not chip of fly off

• Regular documented inspection of hand tools

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HAND-HELD POWER TOOLSHAND-HELD POWER TOOLS

HAZARDS:

• Electrical hazards; shock, burns… etc

• Mechanical entanglement in rotating parts

• Dust & particles flying off cutting or drilling areas; inhalation & eye injuries.

• Cut wounds in case of contact with sharp blades.

CONTROL:

• Protect against electric shock; isolation, grounding.

• Disconnect when not in use.• Regular maintenance,

inspection, check & report & report defects.

• Use the right tool for the job• Maintain clean & tidy work

area.

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MACHINERY HAZRADSMACHINERY HAZRADS

MECHANICAL:

• CRUSHING

• SHEARING

• CUTTING

• ENTANGLEMENT

Entanglement & trapping

Pulley & belt

• TRAPPING• IMPACT• STABBING• EJECTION

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MACHINERY HAZARDSMACHINERY HAZARDS

NON-MECHANICAL:

• Manual Handling & Lifting

• Electricity / Fire / Explosion

• Noise / Vibration

• High / Low temperature

• Dusts / Fumes / Mists

• Biological; bacteria, virus… etc

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MACHINERY SAFEGUARDSMACHINERY SAFEGUARDS

• FIXED GUARDS:

simple physical barrier prevents access to dangerous parts of the machine

• ADJUSTABLE GUARDS:User adjusted / self adjusted

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• Two-handed control devices: require the operator to have both hands on the controls (safe place) before the machine can be operated

• Interlocking Guards: movable guard, whose movement is connected to the power control of the machine

• Trip devices

MACHINERY SAFEGUARDSMACHINERY SAFEGUARDS

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Operation controls & the working place:•Equipment controls to be easily reached from any operating position.•Not to permit accidental start up of equipment.•Adequate Red Emergency stop buttons•Be clearly marked to show what they do•Equipment should be stable; bolting or clamping•Maintain house keeping (clear & unobstructed) at all times•Adequate light &ventilation, clean & tidy up the equipment if not in use•Controls to be isolated from high risk operations e.g. put the controls in a closed glass control rooms, use remote controls… etc.•Provide adequate work instructions & Clear warning signs.

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Hand Tools Hazards Hand Tools' Controls Misuse & poor maintenance; Broken handles e.g. can cause a hammer handle to fly off Cut wounds on incorrect use of saws, knives & chisels. Slipping toolsstab wounds Flying particles that hit the eyes from breaking up

stones/concrete Electric shock or burns when using poorly isolated tool in

electrical work. Incorrect use of hand tools due to lack of training &

instructions.

All tools to be suitable for the purpose Protected & isolated for electrical use Good quality material which will not chip of fly off Use of safety knives with enclosed blades. Regular documented inspection of hand tools Proper storage to prevent damage or corrosion All users to be properly trained in the use of hand tools.

Hand-held Power Tools' Hazards Hand-held Power Tools' Controls Electrical hazards; shock, burns… etc Mechanical entanglement in rotating parts Dust & particles flying off cutting or drilling areas; inhalation

& eye injuries. Cut wounds in case of contact with sharp blades. Manual Handling & hand to arm vibration risks. Tripping hazards; from extended cables. High noise levels.

Protect against electric shock; isolation, grounding. Disconnect when not in use. Regular maintenance, inspection, check & report & report

defects. Use the right tool for the job Maintain clean & tidy work area. Only use accessories & parts recommended by manufacturer. Do not abuse power cables; do not carry the tool by the power

cable, do not pull plug from the cable. Use correct PPE; safety glasses, gloves, respirators & dust

masks… etc

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Mechanical HazardsMechanical HazardsEN tanglementT rapsShearing, drawing in, crushingI mpactC ontactFriction, abrasion, cutting and stabbing, punctureE jection

Remember: ENTICE

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Mechanical Hazards:Mechanical Hazards:ENtanglementENtanglement

ENtanglement: Clothing, Hair, Jewellery getting wrapped around machinery

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Mechanical HazardsMechanical Hazards::TrapsTraps

Traps involve:

Shearing

Crushing

In running nipsDrawing in

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Mechanical Hazards: ImpactMechanical Hazards: Impact

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Mechanical Hazards: ContactMechanical Hazards: ContactContact Injuries:Burns

Lacerations (tear)

Abrasions

Puncture wounds

Cuts

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Mechanical Hazards: EjectionMechanical Hazards: Ejection

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Entanglement Contact

TrappingEjection

Abrasive Wheel (Grindstone)Abrasive Wheel (Grindstone)Machinery Mechanical Hazards

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Mechanical Hazards Drawing-InMechanical Hazards Drawing-In

EntanglementCrushingDrawing in

Shearing

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2] Non-mechanical Machinery hazards:

•Manual Handling & Lifting•Electricity / Fire / Explosion•Noise / Vibration•High / Low temperature•Dusts / Fumes / Mists•Biological; bacteria, virus… etc•Radiation; ionizing/non-ionizing•Psycho-somatic effects•Ergonomics

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Preferred order of GuardingPreferred order of Guarding

FixedInterlockAutomaticTrip (Safety device)

BS EN ISO 12100-2:2003

Remember: FIAT30

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• Fixed Guards: simple physical barrier prevents access to dangerous parts of the machine, difficult to remove & almost maintenance free. Its limitation is that it's often left off by maintenance staff.

• Adjustable Guards: user adjusted; fixed or movable which are adjusted by user for a particular operation, its limitation is that it needs frequent adjustment. Self adjusting guards; adjusts itself to accommodate the passage of material for instance, it still may allow access to dangerous parts & requires careful maintenance.

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• Interlocking Guards: movable guard, whose movement is connected to the power control of the machine; the machine will not operate till the guard is closed. Limitation is that they need constant check to ensure they are operating.

• Trip Devices: detects when a person approaches close to danger point & stops the machine before injury occurs. Could be physical barrier, electrical, Photo-electric with sensors or pressure-sensitive mats.

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• Two-handed control devices: require the operator to have both hands on the controls (safe place) before the machine can be operated. Limitation is that they only protect the operator's hands; therefore it is critical that the machine's design does not allow any other part of the operator's body to enter the danger zone during operation.

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-"Bolt on" guards are less effective in reducing risks, more likely to inhibit normal operations & may represent hazards in themselves. It is best to consider "Built in" guards in the design phase.

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-It is critical that all users of guarded machinery get adequate training, information & work instructions on how to use & safely deal with guarded machinery prior to starting operations.

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Operators' responsibilities:•Take reasonable care of themselves & others who might be affected by their work.•Use Equipment properly & stick to work instructions.•Attend proper training & use the information provided•Report to the employer any hazardous situations or unsafe conditions•Use provided PPE•Cooperate with the employer & attend safety meetings

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Basic Principles for Guards & Safety devices:•Compatible with the process.•Have adequate strength•Allow maintenance & servicing without guard removal•Does not increase the risk or restrict user's view•Is not easy to be by-passed

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"The use of PPE is crucial as the last line of defense to control machinery & hand held tools hazards; •Coveralls; protects against loose parts of clothing getting entangled.•Safety Glasses; protects against ejected parts of material.• Ear protection; protects against machinery noise•Safety boots; protects against feet crushing by pieces of work falling onto them•Hair nets; prevent hair from getting entangled in moving machinery parts.

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Machinery Hazards associated Appropriate Safeguards

1]Office Photocopier

Contact with moving parts; when clearing a paper jam.

Electrical; during maintenance / clearing jam

Ultraviolet light Health hazards; toner &

ozone Noise & Ergonomics

All enclosing case Access doors are

interlocked; machine switches off automatically when gaining access.

Isolation of internal electrics

Maintenance Use the cover to

protect from UV

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2] Office Document Shredder

Drawing in between rotating cutters.

Contact with rotating cutters.

Electrical & Noise Possible dust from

cutting.

Enclosed fixed guards around the cutters

Interlocks fixed to the cutter heads

Trip device; starts the machine when paper is fed in.

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3] Manufacturing & maintenance – Bench top grinder

Contact with the rotating wheelabrasion

Drawing in between the rotating wheel & a badly adjusted tool rest.

Bursting wheelejecting fragments.

Electrical; faulty wiring.

Noise & Vibration Health hazards;

Dusts Fires due to sparks &

hot fragments.

Wheel enclosed as much as possible in strong casing

Adjustable screen to be fitted over the wheel.

Only proper trained personnel should use it

Maximum speed to be marked on the machine

Adjustable tool rest to be adjusted as close as possible to the wheel

Implement Portable Electrical Testing

Dust extraction

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Manufacturing & maintenance – Pedestal Drill

Entanglement around rotating parts

Contact with drill or work piece; cutting or puncturing

Being struck by work piece

Electrical; faulty wiring/lack of grounding

Dusts

Motor & drive to be fitted with fixed guards.

Spindle to be guarded by an adjustable guard

Use clamp/vise to secure work piece

Use goggles Keep the machine

clean, tidy & unplugged when not in use

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Agricultural / Horticultural Cylinder mower

Contact & Entanglement with rotating blades

Trapping of hands by rotating blades

Health hazards; dusts, fumes & hay

Noise & Vibration Manual Handling /

Ergonomics.

Design should restrict access to bottom blade trap.

Drives & motor to be enclosed in fixed guard

Use suitable dust mask & only run engine in open air

Silencers for noise

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Agricultural / Horticultural Strimmer

Entanglement with the rotating part.

Cutting on contact with the cutting head

Ejection of particles Noise / Vibration Ergonomics;

musculoskeletal Health hazards from

herbicides & or/ animal faeces

Moving engine parts enclosed

Rotating head to have fixed top guard

Run engine only in open air

Proper safety boots Anti-vibration handles Dust masks & hearing

protection & gloves

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Retail - Compactor Crushing; between ram & machine sides.

Trapping & Entanglement with rotating parts

Electrical Manual Handling

Access doors to loading area to be interlocked.

Dives of motors to be properly guarded

Regular inspection & testing

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Retail – Check out conveyor system

Drawing in between belts & rollers

Entanglement Electrical Manual Handling

All traps between belt & rollers to have fixed or interlocked guards

Emergency Stop Buttons

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Construction – Cement mixer

Entanglement with the moving parts of motor

Trapping Dusts / Noise Manual Handling Eye injury; in case of

cement splash

Design should allow the user to see anyone in the trapping area.

Drum gearing to be enclosed

No one allowed to stand on machine

Goggles & PPE

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Construction – bench mounted Circular saw

Contact with the cutting blade

Ejection of the work piece

Entanglement with moving parts of the motor

Dusts / Noise / Vibration

Electric; faulty wiring, grounding.

Fixed guards to the blade below the bench

Adjustable top guard to the blade above the bench

Extraction ventilation for wood dust

Safety glasses & Dust masks