1.

0 Unit 12: Work equipment hazards and control

1.0 Unit 12: Work equipment hazards and control

Overall aims. Understand:

the hazards and risks from the use of work equipment; the basic measures to be taken to minimise the risks.

Specific intended learning outcomes. Be able to:

outline the general principles for the selection, use and maintenance of work equipment; outline the hazards and controls for hand-held tools; describe the main mechanical and non-mechanical hazards of machinery; describe the main methods of protection from machinery hazards.

Reference: Safe Use of Work Equipment (ACoP) (L22), HSE Books. ISO 12100 -1: 2003, Safety of machinery, basic concepts, general principles for design, basic terminology, methodology" ISO 12100- 2: 2003, Safety of machinery, basic concepts, general principles for design, technical principles Ambient Factors in the Workplace (ILO Code of Practice), ILO.

Tuition time: 7 hours.

1.2 Introduction to Work equipment hazards and control

The purpose of this unit is to provide discussion, assistance and guidance for the safety of machinery, especially protective systems and guarding. Work equipment means any machinery, appliance, apparatus or tool and any assembly of components. The scope of work equipment is therefore extremely wide and includes:

hand tools such as hammers, knives, handsaws, scissors, wrenches; single machines such as drilling machines, circular saws, lathes, photocopiers, food slicers, power presses, paper guillotines, vacuum cleaners, printing presses, chain saw; apparatus such as laboratory apparatus (e.g. bunsen burners, autoclaves), high temperature apparatus (melters, kilns), furniture, kettles, cameras; lifting equipment such as hoists, passenger lifts, lift trucks, elevating work platforms, lifting slings, vehicle tail lifts; other equipment such as ladders, pressure water cleaners, personal protective equipment, trolleys, AV equipment; an installation such as scaffolding, pressure systems, a series of inter-connected machines; mobile work equipment such as lawn mowers, dumper trucks, road sweepers, tractors; and motor vehicles (vans, mini-buses); and towed equipment (gang-mowers, trailers)

The term work equipment does not apply to animals, substances, structural items, private vehicles as they are not classified as work equipment.

Safe use covers the full range of risk, i.e. not just the moving blade of the band saw, or the fragments ejected from/of the abrasive wheel, but the pressure cooker exploding, the ladder toppling, the radiation from the UV lamp, the hot surface of the cooker, the sharp edge of a knife, the load falling from a chain block, the broken laboratory glassware, the scaffold collapsing, the tractor overturning.

Use can be defined as "any activity involving work equipment and includes starting, stopping, programming, setting, transporting (used for), repairing, modifying, maintaining, servicing and cleaning"

Work Equipment can be defined as "any machinery, appliance, apparatus, tool or installation for use at work".

(Machinery may be described as equipment with moving parts powered by an energy source.) Please select the correct missing words, in order, for the sentence below Work _________ means any __________, appliance, apparatus or tool and any _________ of ___________. Equipment Components Machinery Assembly

1.3 The Supply of Machinery (Safety) Regulations 2008

egulations governing the supply of machinery were

first enacted in 1992 and subsequently amended in 1994. In 2006, a new EU Directive made amendments to the regulations and this Directive was adopted into British law in December 2009. It is summarised below:

The Supply of Machinery (Safety) Regulations 2008

The Regulations apply to:
(a) machinery described as; (i) an assembly, fitted with or intended to be fitted with a drive system other than directly applied human or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined together for a specific application; (ii) an assembly as referred to in subparagraph (i), missing only the components to connect it on site or to sources of energy and motion; an assembly as referred to in subparagraph (i) or (ii), ready to be installed and able to function as it stands only if mounted on a means of transport, or

(iii)

installed in a building or structure; (iv) assemblies of machinery as referred to in sub-paragraphs (i), (ii) and (iii) or partly completed machinery, which, in order to achieve the same end, are arranged and controlled so that they function as an integral whole; an assembly of linked parts or components, at least one of which moves and which are joined together, intended for lifting loads and whose only power source is directly applied human effort; interchangeable equipment described as; devices which, after the putting into service of machinery or of a tractor, are assembled with that machinery or tractor by operators themselves in order to change its function or attribute a new function, in so far as they are not tools.

(v)

(b)

(c) safety components described as components; (i) which serve to fulfil a safety function; (ii) which are independently placed on the market; (iii) the failure or malfunction of which endangers the safety of persons; and

(iv) which are not necessary in order for the machinery to function, or for which other components which do not fall within the previous subparagraphs may be substituted in order for the machinery to function; As noted above, the definition of safety components is now backed up in the 2008 Regulations by an indicative list of examples of products that fit this definition (see Annex E). (d) lifting accessories described as components or equipment that; (i) are not attached to lifting machinery; (ii) allow a load to be held; (iii) are placed between the machinery and the load or on the load itself, or are intended to constitute an integral part of the load; and (iv) are independently placed on the market (e) chains, ropes and webbing described as being; designed and constructed for lifting purposes as part of lifting machinery or lifting accessories removable mechanical transmission devices described as;

(f)

Removable components for transmitting power between selfpropelled machinery or a tractor and another machine by joining them at the first fixed bearing (when such components are placed on the market with a guard the components and the guard together shall be regarded as one product). (g) partly completed machinery described as; drive systems and other assemblies which (a) are almost machinery;

(b) cannot in themselves perform a specific application; and (c) are only intended to be incorporated into or assembled with other machinery or other partly completed machinery or equipment, thereby forming machinery.

Exceptions:
The new Regulations do not apply to machinery or safety components:

(a)

as specifically listed in Annex B

(b)

that are not placed on the EU market or put into service in it, eg that are in transit through it/sold at auction for non EU use

(c)

if, or to the extent that, Community directives other than the Directive, wh2ich apply to them make more specific provision than the Directive in connection with the hazards referred to in the Essential Health and Safety Requirements of the UK Regulations

(d)

that are placed previously on the market or put into service in any EU member state prior to 29 December 2009 i.e second-hand machinery

(e)

that are in the supply chain prior to 29 December 2009 but unused

(f)

that are being exhibited at trade fairs and exhibitions which do not comply with the Regulations, provided that visible sign clearly indicates that it does not comply, that it is not for supply until it has been brought into conformity and takes adequate safety measures to ensure that it does not kill or injure any person.

General requirements
The Regulations make it an offence for a responsible person to supply machinery, partly-completed machinery or safety components unless they comply with the Regulations, i.e. they have the requisite technical file, Declaration of Conformity, EC Type-examination certificate, Declaration of Incorporation as appropriate, is CE marked and is in fact safe (see Annex A).

How to comply with the Regulations

Overview of conformity assessment procedures
The responsibility for demonstrating that machinery complies with the Directive rests on the 'responsible person' (see Annex A) applying the essential health and safety requirements (See Annex C).

Methods of Assessment
There are three methods of conformity assessment under these Regulations with the choice of method available to the responsible person being dependent for the most part on whether the machinery in question falls within Annex D. Thus for machinery: - not included in Annex D, or included in it but manufactured wholly in accordance with transposed harmonised standards (see Annex A), see method 1 - included in Annex D but either not manufactured wholly in conformity with transposed harmonised standards or was manufactured to be in conformity by not opting to use method 1, see method 2 - included in Annex D and manufactured using a Full Quality Assurance system, see method 3.

Method 1 -

Self Assessment

A responsible person, applying the general principles (see page 14) and having regard to standards (see page 10), undertakes a risk assessment against the Essential Health and Safety Requirements (EHSRs - see Schedule 2, Part 1 of the Regulations), produces a technical file having applied the necessary internal checks (see Annex F), produces a Declaration of Conformity (see Annex G) and affixes the CE mark to the product thus declaring compliance to the Regulations.

Declaration of Incorporation
Where the machinery is incomplete and is intended for incorporation into other machinery or assembly with other machinery to constitute machinery covered by the Regulations, the responsible person must draw up a Declaration of Incorporation for each machine (see Annex H) in this case the partly complete machine must NOT be CE marked. This option is not available for interchangeable equipment modifying the function of the machine or machinery which can function independently.

EC Type examination

Where a responsible person makes a product which is not manufactured wholly in accordance with transposed harmonised standards, i.e. they have not been published in the OJ (see Sources of Reference) they will be required to have it assessed by a Notified Body (see Annex A). If compliant the Notified Body will issue an EC-type examination certificate (see Annex I). This method is also an option open to a manufacturer for machinery that is wholly manufactured to a harmonised standard.

Method 3 -

Full Quality Assurance

A responsible person, having manufactured a product using a full quality control system, has that system assessed by a NB which has been accredited for this type of activity by UKAS. The NB will arrange the issue of the necessary documentation and CE marking (see Annex J).

The marking is as illustrated in diagram 1, below. Except for small-scale machinery, the marking may not be smaller than 5 mm in its vertical height. CE marking must be affixed in a distinct, visible, legible and indelible manner. The CE marking should not be affixed to machinery for which a declaration of incorporation has been issued. The Regulations make it an offence to affix a mark to machinery which may be confused with CE marking.

Machinery or safety components that comply with the Regulations may also be subject to other Community Directives. For example, an electric machine permanently installed in a building would need to comply with legislation implementing the Construction Products and Electromagnetic Compatibility Directives as well as any other existing relevant legislation. In such cases the CE marking indicates that the requirements of those other Directives have also been complied with. Machinery bearing CE marking and accompanied by the EC declaration of conformity can be presumed to satisfy the provisions of the Machinery Directive unless there are reasonable grounds for suspecting otherwise.

A person who either supplies machinery which does not bear CE marking, or does so but there is doubt as to validity is required, if requested by an enforcement authority from any EU Member State, to provide any available information that will allow it to determine its compliance. Failure to supply such information could, as a minimum, lead to restrictions being placed on its use which, in turn, could also lead to criminal prosecution. The conformity assessment mechanisms available are shown in diagrammatic form in Annex K. Because partly completed machinery is only intended to be incorporated into or assembled with other machinery, or partly completed machinery, it should not be CE marked. Instead the responsible person should complete a Declaration of Incorporation (see Annex H). It is for the responsible person to CE mark the whole product at the point when it is placed on the market/put into service - the Declaration of Incorporation forming part of the technical file.

 The Directive amends the Lifts Directive 95/16/EC, and now regulates construction site hoists, and lifts with a travel speed no greater than 0.15m/s.

Portable cartridge-operated fixing and other impact machinery are no longer excluded from the Machinery Directive.

The new Machinery Directive now identifies electrical and electronic products types to which the LVD (2006/95/EC) only should be applied.

The revised Essential Health & Safety Requirements (EHSRs) now effectively includes the "essential requirements" of the LVD within the EHSRs.

The Directive introduces the term 'partly completed machinery' to better define and explain 'machinery... which cannot function independently ' as used in the old Directive where a Declaration of Incorporation is required.

There are significant additions and changes to the EHSRs that will affect machine design including requirements for guarding and control systems. The supplementary EHSR's have also been subject to some changes.

The content & detail of the EC Declaration of Conformity is changed.

In general the requirement for the CE mark remains unchanged except that it must now be affixed 'in the immediate vicinity of the name of the manufacturer or his authorised representative.'

The new directive still lists categories of machinery to which special procedures must be applied (Annex IV) but, significantly, the necessity to involve a Notified Body has been removed if the machinery is manufactured in accordance with harmonised standards.

Where a Notified Body has been involved, there is a new requirement for a review of the EC type-examination certificate every five years.

Machinery not complying with the Regulations cannot be legally sold in any Member State, including the United Kingdom, even if it is made in the United Kingdom. The annexes to the 2008 regulations are lengthy and can be accessed and reviewed in their entirety here: http://www.berr.gov.uk/files/file52968.pdf

1.3.1 Ensuring a suitable provision of work equipment

CE Marking
The marking is as illustrated in diagram 1, below. Except for small-scale machinery, the marking may not be smaller than 5 mm in its vertical height. CE marking must be affixed in a distinct, visible, legible and indelible manner. The CE marking should not be affixed to machinery for which a declaration of incorporation has been issued.

The Regulations make it an offence to affix a mark to machinery which may be confused with CE marking.

Machinery or safety components that comply with the Regulations may also be subject to other Community Directives. For example, an electric machine permanently installed in a building would need to comply with legislation implementing the Construction Products and Electromagnetic Compatibility Directives as well as any other existing relevant legislation. In such cases the CE marking indicates that the requirements of those other Directives have also been complied with.

Machinery bearing CE marking and accompanied by the EC declaration of conformity can be presumed to satisfy the provisions of the Machinery Directive unless there are reasonable grounds for suspecting otherwise.

A person who either supplies machinery which does not bear CE marking, or does so but there is doubt as to validity is required, if requested by an enforcement authority from any EU Member State, to provide any available information that will allow it to determine its compliance. Failure to supply such information could, as a minimum, lead to restrictions being placed on its use which, in turn, could also lead to criminal prosecution. The conformity assessment mechanisms available are shown in diagrammatic form in Annex K.

Because partly completed machinery is only intended to be incorporated into or assembled with other machinery, or partly completed machinery, it should not be CE marked. Instead the responsible person should complete a Declaration of Incorporation (see Annex H). It is for the responsible person to CE mark the whole product at the point when it is placed on the market/put into service - the Declaration of Incorporation forming part of the technical file.

1.4 Essential Health and Safety Requirements (EHSRs)

Are summarized below.

Machinery must be constructed so that it is fit for its function and can be "adjusted and maintained" without risk. The aim is to eliminate any risk of accident throughout the foreseeable lifetime of the machinery, including the phases of assembly and dismantling, even where risks of accident arise from foreseeable abnormal situations.

This means that the manufacturer must: (a) eliminate or reduce risks as far as possible (i.e. the design of the machinery should ensure that the equipment is inherently safe in use); control risks which cannot be eliminated by use of appropriate safety measures; inform users of risks which cannot be totally eliminated and indicate whether any particular training or Personal Protective Equipment (PPE) is required.

(b)

(c)

Machinery should be designed and constructed so as to prevent it from being used in any way that was not intended. The written instructions should also prohibit any abnormal use of equipment, drawing attention to any possibilities for this which might exist. Under the conditions in which the machinery should be used, "the discomfort, fatigue and psychological stress" of the operator should be alleviated by application of sound ergonomic principles. The design should also take into account the physical restraints placed on the operator by use of PPE. Any "essential special equipment and accessories" must be supplied so that the machinery can be safely and properly adjusted, maintained and used.

It is also essential that neither the materials used in machinery construction nor the products used and created by the machinery process should constitute a danger. Lighting suitable for the tasks must be an integral part of the machinery. Controls must be "safe and reliable", designed so that "errors in logic do not lead to dangerous situations" and constructed so that they can "withstand the rigours of normal use and external factors"; they must be, for example:

clearly visible, easily identifiable and properly marked; positioned so that they may be operated safely and their operation does not cause additional risk.

Also, it should only be possible to:

START a machine by "voluntary actuation of a control" (i.e. a decisive action on the part of an operator); STOP a machine by means of a control (fitted to the machine) which will bring it safely to a complete halt.

Each machine must be fitted with one or more emergency stop devices to avert any danger. In an emergency, the following points should be taken into account:

Interruption of the power supply must not allow the machine to start inadvertently, or allow parts of the machine or work piece to be ejected.

Failure of a control circuit must not lead to a dangerous situation and automatic and manual protective devices must remain fully effective.

Machinery must be stable and constructed so that the various parts can withstand the stresses for which they are designed. The manufacturer must indicate in the instructions the type and frequency of inspection and maintenance the machinery requires. The manufacturer must also indicate which parts of the machinery are subject to wear and give details of the criteria for any replacement.

1.4.1 Designing Work Equipment

The design should incorporate precautions to control the risks due to break-up during operation, falling or ejected objects, edges or angles and moving parts.

1.

Guards and protection devices must:

be robust; not give rise to any additional risk; be difficult to circumvent or put out of service; be located an "adequate distance from the danger zone."

2.

Fixed guards must be securely held in place by a system that can only be opened using the appropriate tools. Type A movable guards should remain fixed to the machinery when open and should have a locking device to prevent any accessible moving parts from starting. Type B movable guards must be incorporated into the control system so that moving parts cannot start while they are still accessible and that they cannot be reached once they have started to move. Failure of a component must prevent the starting of moving parts, or stop the moving parts if they are in motion. They should only be adjustable by an intentional action, such as the use of a key or tool. Adjustable guards restrict access to moving parts where operator intervention is necessary. They must be easily adjustable, either manually or automatically, without the use of tools. Protection devices must be incorporated into the control system so that the moving parts cannot start whilst they can still be reached by the operator and that the operator cannot reach the moving parts once they have started. It should only be possible for an authorised person to adjust the protection devices intentionally, i.e. by following a prescribed action like using some sort of tool. If a protective device should fail, that failure should either prevent the machine from starting or immediately stop its moving parts.

3.

4.

5.

6.

Precautions to control risks from other hazards should be taken. These hazards would include

electricity, extreme temperatures, fire, explosion, noise, vibration, radiation, dust, gases.

Any points at which adjustments are made or machinery is lubricated and maintained must be positioned some way from the danger zone.

Maintenance, repair and cleaning operations must be possible when the machinery is at a complete halt and all moving parts are still. Diagnostic fault finding equipment should be used where necessary.

Machines must be provided with safe and sufficient means of access, such as stairs, to all areas used for production, adjustment and lubrication. Places of work must be designed so as to prevent falls.

It must be possible to isolate machinery from all energy sources by some means. These "isolators" must be easy to recognise and it should be possible to lock them where it is likely that reconnection to a power supply would expose people to danger.

Machines must be designed and constructed so that any operator intervention is kept to a minimum and that it is safe. Cleaning internal parts of machinery should be possible without having to go inside it.

1.5 The extent of information in relation to work equipment

Information for controlling machinery should be clear and easy to understand. There should not be complex or excessive information which is difficult for operators to assimilate and - consequently - impossible for them to act upon. Unsupervised machinery must be equipped to give an acoustic or light signal if a person is endangered in any way. Pictograms should be used to warn of residual risks or risks from hazards that are not obvious, e.g. electrical, radioactivity or pressure in hydraulic systems. Warnings should also be issued in the language of the country in which the machinery is to be used (accompanied, if required, by warnings in languages which the operators will understand). All machinery must be marked with items such as the name and address of the manufacturer, the CE mark, the type and serial number. All machinery must be accompanied by instructions which must repeat the information marked on the machinery and include all additional information required to maintain the equipment. The instructions must cover:

the foreseeable use of the machine; the workstation(s) likely to be occupied; safety procedures for putting the machinery into service; its handling, assembly, dismantling, adjustment and maintenance; characteristics of tools; and training requirements; all necessary drawings and diagrams, with particular regard for safety; information concerning the machinery's emission of noise which can then be used for reducing noise and vibration.

Where machinery may also be used by non-professional operators, the instructions should take into account the general level of education/expertise that can be expected from such users. There are additional health and safety requirements for certain categories of machinery, such as that used for agri-foodstuffs processes, hand-held machinery, woodworking machinery, mobile machinery, lifting machinery and machinery posing special hazards.

1.5.1 Classification Scheme for Errors

A study of human performance and human error by HSE (HS(G)48: (Human Factors in Industrial Safety) has produced a classification scheme into which most errors fall. 1. Lapses of attention. The operator's objectives and intentions are correct, but a lapse in concentration can cause an accident. Highly-skilled workers can be prone to errors of this type. Mistaken actions. Performing a wrong action whilst under the impression that it is the right one. Misperceptions. These tend to occur under stress when a mass of information competes for an individual's attention or when a pre-conceived idea blocks out other information. This often occurs where the individual does not fully understand the process. Mistaken priorities. These errors are usually the result of a conflict of priorities within an organisation, when other factors can sometimes take precedence over safety arrangements. Wilful actions. Usually, accidents which occur in this instance are the result of taking short cuts through procedure, when an operator believes that the benefits of ignoring the rules outweigh the apparent risk.

2.

3.

4.

5.

1.6 Training
Operators should be fully informed of the hazards presented by machinery and the risk control measures employed. Training in the recognition of hazards and correct working procedures is an important part of risk control. Operators have a responsibility for their own safety and that of others who may be affected by their activities. They should be fully involved in the risk management process. Although performance monitoring is an important function of supervision, communication and assistance should not be neglected.

PPE should be supplied where its use results in a beneficial risk reduction when all other practicable precautions have been taken.

1.7

Maintenance

Maintenance Operations and Personnel.

By their very nature, maintenance operations are likely to be hazardous as they involve work on equipment that is not in its normal operational mode. This applies particularly when all of the equipment cannot be isolated during the maintenance task or needs to be kept operational to analyse the effects of changes in control parameters. Static plant can conceal hazardous substances or hazardous conditions, such as pressurised hydraulics, in spite of being isolated from sources of energy. Computer-controlled equipment may be static but can start suddenly and without warning. Maintenance tasks must be assessed for such inherent risks and suitable protective measures taken, whether by additional physical safeguarding, personal protective equipment or systems of work. It is well-known that a substantial number of fatal accidents occur during maintenance operations.

Maintenance personnel must be trained for the tasks they are expected to perform, particularly where specific risks exist. Ideally, they should be part of a multi-skilled team and the management culture should allow for the inclusion of manufacturing personnel within this team. Only when maintenance becomes fully integrated into the operational functions of an organisation will the real cost benefits be realised.

1.7.1 Maintenance & Provision and Use of Work Equipment Regulations 1998
Employers are required to ensure that work equipment is maintained in an efficient state, in efficient working order and in good repair and that where machinery has a maintenance log, the log is kept up to date. The need to maintain equipment so as to avoid risks to health and safety is essential as is the keeping of records where risks exist or where records are specified. There may also be a requirement for equipment to undergo periodic testing and/or inspection. The proper management of maintenance is often neglected, resulting in equipment that is unsafe, unreliable, unproductive and unprofitable. Some companies regularly spend more on maintaining existing plant and equipment than they do on new purchases and much of this expenditure can be wasted because of poor planning. In order for a maintenance management programme to be effective, it must be planned in the same way as any other critical business activity that has a direct influence on profitability. Planning should begin with the preparation of a register of plant and equipment, and maintenance schedules (including tests and examinations) for individual items should be devised. This initial preparation can then be developed into an integrated programme which will include budget organisation and stock control for spare parts. When equipment is reliable, it is more likely to be safe. Unexpected equipment failure also increases costs and will create unknown and unexpected hazards, especially if failures occur in safety-related devices such as guards, controls, overload protectors and ventilation equipment. All electrical and mechanical systems go through a life-cycle of a short

period of early failures followed by an extended period of random failures ending in another short period of wear-out failures. Early failures are usually due to faults in design, manufacture or installation. Wear-out failures can be attributed to operational conditions, including poor maintenance. In devising a maintenance strategy, an understanding must be gained of how failures occur in a system and what the end result of a failure is likely to be, so that maintenance tasks can be tailored accordingly. Manufacturers of equipment will have prepared their maintenance programmes from experience gained in the past. Complicated equipment and prototype or pilot-plant processes cannot benefit fully from this accumulated prior knowledge. Assessments are best conducted as a team exercise on the "what if?" principle and should involve operators, supervisors and maintenance personnel. The failure of protective safety devices may not have a direct effect on the operational functions of a plant and may remain unnoticed until their nonfunction is combined with another failure, thus creating a primary hazard. Proper maintenance of safety devices is therefore extremely important. Where a hazard is so great that it needs more than one safeguard to control the risk, then all these devices must be monitored so that failure of one will become immediately apparent and the reduction in protection can be taken into account. The monitoring system used will depend on the severity of outcome of a failure and can range from the use of simple indicator lights to the use of automatic and continuous computer data evaluations. Failure of operational equipment will certainly lead to some economic loss, which may be tolerated. It may, however also create a hazardous situation leading to a risk to the operator, which cannot be tolerated. In a complex system, where failure can lead to catastrophic consequences, it is essential that the constituent parts are of the highest attainable reliability and that the system contains the fewest possible number of parts. The maintenance programme applied to such a system must take into account the reliability factors to ensure that constituent parts are replaced or repaired before failure can occur. Where high standards of reliability are essential, then human performance will have a great influence on the standard achieved. Poor equipment design, the improper functioning of its displays and controls and faulty decision-making on the part of its operator, can all have a significantly negative influence on safe and reliable operation.

Employers must ensure that there is relevant training and instruction of operators, and that they have a clear understanding of specific responsibilities.

1.7.2 Maintenance Programmes

Can be divided into five distinct types.

1. Unscheduled or breakdown maintenance is usually disruptive to production and requires immediate remedial action. This may be appropriate where the cost of replacement parts is high, there are alternative means of production available and the disruption does not cause a great deal of inconvenience. Scheduled or routine maintenance consists of: (a) (b) (c) (d) cleaning; adjustment; lubrication; inspection and testing.

2.

This is probably the most common form of maintenance strategy. For simple equipment, this maintenance is adequate unless there are special circumstances. 3. Planned preventative maintenance includes the tasks listed in scheduled maintenance (above), and in addition, the planned periodic replacement of wearing parts prior to failure, based on known past failure history. Predictive maintenance is based on a monitoring system to detect deterioration in components so that these can be replaced before failure occurs. This can be more economical on costly complex plant than preventative maintenance because components are only replaced when

4.

needed and not on a time-based schedule. Monitoring systems usually measure physical properties such as vibration and temperature. 5. Improvement maintenance is aimed at reducing or avoiding maintenance tasks by eliminating problems at source by a process of redesign and modification to suit particular circumstances.

Maintenance Record:
This record should contain the maintenance history - with details of the work undertaken - for each item of plant or equipment. Maintenance activities should be carried out in accordance with devised schedules to ensure safety and reliability.

1.8 Tests and Examination

For ease of administration, tests and examination should be incorporated into the maintenance schedules. Relevant statutes must be consulted to ensure legal compliance. Legislation may require that any lifting equipment which is exposed to conditions causing deterioration which is liable to result in dangerous situations is thoroughly examined at intervals ranging from 6 to 12 months, depending on what it is, and is subject to inspection by a competent person at suitable intervals between those thorough examinations. In specified circumstances, where the safety of lifting equipment depends on the installation conditions, it must be thoroughly examined after installation and before being put into service for the first time. Portable electrical appliances, electrical plant and wiring installations may be subject to test and inspection of varying intervals depending on use. For instance, hire equipment should be tested and inspected before each hire, and double-insulated equipment used in low-risk environments - such as offices - may only need a formal inspection without test every 4 years. Guidance literature on test and inspection intervals for electrical equipment is available from HSE.

1.8.1
Type of Plant, Machinery and Equipment
Construction Sites

Examination Schedules
Education Office Buildings Theatres & Cinemas

Pressure Systems

Steam Boilers and steam ovens Steam Pressure Plant Hot Water Boilers (>100oC) Air Pressure Plant Air Conditioning/Refrigeration Plant (>25kW) Other Pressure Systems 26 6 6 12 12 6 6 6 6 12 12 12 * * 26

14 26 14 26 26

14 26 14 26 26

14 26 14 26 26

26 6 6 12 12 6 6 6 6 12 12 12 *

26 6 6 12 12 6 6 6 6 12 12 12 *

26 6 6 12 12 6 6 6 6 12 12 12 12

Lifting Passenger Lifts Equipment Other Equipment which can be used to lift persons Cranes Other Lifting Equipment Lifting Accessories (Tackle) Process Machinery Power Presses and Press Brakes Other Power Presses Guillotines (Printing Works) Guillotines (Factories) Injection Moulding Machines Guarded Process machinery Electrical Electrical Installations and Equipment Portable Electrical Appliances

1.9 Other key factors

Suitable materials should be used for construction and operation. Adequate lighting and handling facilities should be provided. Controls and control systems must be safe and reliable. Machines must not be capable of starting up unexpectedly and should have one or more emergency stop devices fitted. Consideration must be given to complex installations where processes upstream or downstream can affect the safety of a machine. Failure of a power supply or control circuit must not lead to a dangerous situation. Machines must be stable and capable of withstanding foreseeable stresses. They must have no exposed edges or surfaces likely to cause injury. A control is the manual actuator that the operator touches to start a machine, change a function, such as speed or direction and finally to stop the machine. It may operate directly but is more often a part of a control system incorporating sensors, limit devices, brakes, clutches and other components. A control may consist of nothing more than a simple on/off switch. New equipment will probably be supplied with appropriate controls; machines consisting of linked sub-assemblies may need a systematic risk assessment to determine the best positions for controls. The development of programmable electronic systems has brought new and less obvious risks into the workplace that cannot be easily assessed. Controls must be positioned out of any danger zone, except those that perform a safety function, such as emergency stop controls. Emergency stop controls should be provided at every control position and their operation should not increase the risk of injury from another source. Operators should have a clear view from the control position so that noone is placed at risk when a machine is started up. On complicated continuous production machinery, this may not be possible and procedures such as signalling will have to be devised to overcome the problem. Standard layouts and markings should be adopted to avoid confusion. Start controls and other functional controls should be constructed and positioned so that they cannot be operated by accident. It must not be possible for a machine to re-start after a stoppage by the re-setting of a protective device or by the restoration of power after a power failure. A stop control should be sited near every start control. Controls must be clearly identifiable and easily distinguishable from each other by positioning, shape, colour, size or labelling and their movement

should be consistent with their effect (i.e. up for up, left for left, etc). Where a control is designed to perform several different actions, such as a programmable electronic system, then the action to be performed must be clearly displayed and subject to a confirmation command where necessary. Components and systems must be reliable to avoid unforeseen and potentially hazardous machine behaviour. They must be chosen to withstand all stresses associated with the use of the equipment. This includes environmental stresses due to impacts, vibration, temperature, moisture, corrosive substances, magnetic and electric interference. In critical processes, control systems must be monitored and the mode of failure of components predicted, so that emergency intervention procedures can be formulated. Consideration should be given to the duplication of components (designed redundancy) so that failure of one will still leave another to perform the protective function. On certain installations, where the start control is in such a position in relation to the equipment that the operator cannot be certain that people are not in the vicinity, it may be appropriate for a warning signal to be given and the machine started through a pre-determined time interlock. Where a malfunction creates a hazard (such as uncontrolled temperature or pressure), sensors should be used to trigger an automatic or audible alarm. The manner and type of any audible or visual alarm signals should be known to all those likely to be affected. Instrument displays and other information devices must be visible from the control position and their function known. The information displayed must be continuous, unambiguous and easily understood. Perception of a machinery hazard can be increased by the use of markings (such as warning words or phrases or recognised pictograms like the wellknown lightning flash denoting electrical hazards). High visibility paint can also draw attention to a hazard.

Positioning of equipment.

Consider - does the siting of a machine present a hazard to people other than an operator? Is there a clear unobstructed workspace? Is there sufficient lighting? Is the lighting casting a shadow from the operator as they perform certain tasks? Is there local lighting fitted to the equipment to ensure sufficient lighting? If there is flickering lighting, what issues may this cause? Imagine working on a lathe; the flicker could be in sequence with the rotation of the work piece which could lead to the perception that the work piece has stopped. The results can be all too easily imagined.

1.10 The responsibilities of users.

All employees are under a duty to take reasonable care for the health and safety at work of themselves and any other people who might be affected by their acts or omissions and to co-operate with their employers and others to enable them to comply with statutory duties and requirements. Additionally, they must not intentionally or recklessly misuse or interfere with anything provided in the interests of health, safety or welfare in pursuance of any aspect of health and safety law. This is made quite clear in Section 8 of the HSW 1974 Act. However, badly-designed or inadequate guarding is a hazard to an experienced operator as well as to a careless worker or a novice. As no safety mechanism is absolutely secure against deliberate misuse or ignorance, a clear understanding of the responsibility of the operator to use machinery in a safe way and not to interfere with safety devices is an important part of the operator's training. It is good practice to document all training, whether it is induction, taskrelated or health and safety awareness. This record should contain details of training received, including refresher training where applicable.

Where successful training results in an award, this should be recorded. Copies of certificates awarded should also be included.

Note: For some tasks, an employer has a particular duty to provide specific training, such as in the case of the mounting of abrasive wheels. The following should also be considered in order to ensure that machinery is used safely. The employee using the machine should have enough information and understanding to enable:

Compliance with the company's health and safety policy. A prompt and accurate response to problems and emergencies concerning the machinery and those near to it. Utilise a safe system of working.

The manager or supervisor should have enough information and understanding to enable:

employees and others to operate the machinery safely and efficiently; a prompt and accurate response to problems concerning the machinery; compliance with the company's own health and safety policy and internal procedures; a prompt and accurate response to an emergency concerning the machinery; elimination or reduction of the risks to visitors; compliance with any statutory requirments; any personal protective equipment necessary to be made available and to be worn correctly; a safe system of working to be observed when using the machinery.

1.11 Hand and Power Tools

Tools are such a common part of our lives that it is difficult to remember that they may pose hazards. All tools are manufactured with safety in mind but, tragically, a serious accident often occurs before steps are taken to search out and avoid or eliminate tool-related hazards. In the process of removing or avoiding the hazards, workers must learn to recognise the hazards associated with the different types of tools and the safety precautions necessary to prevent those hazards.

Hand Tools

Hand tools are non-powered. They include anything from axes to wrenches. The greatest hazards posed by hand tools result from misuse and improper maintenance. Some examples:

Using a screwdriver as a chisel may cause the tip of the screwdriver to break and fly, hitting the user or other employees. If a wooden handle on a tool such as a hammer or an axe is loose, splintered, or cracked, the head of the tool may fly off and strike the user or another worker. A wrench must not be used if its jaws are sprung, because it might slip. Impact tools such as chisels, wedges, or drift pins are unsafe if they have mushroomed heads. The heads might shatter on impact, sending sharp fragments flying.

The employer is responsible for the safe condition of tools and equipment used by employees but the employees have the responsibility for properly using and maintaining tools. Employers should caution employees that saw blades, knives, or other tools be directed away from aisle areas and other employees working

in proximity. Knives and scissors must be sharp. Dull tools can be more hazardous than sharp ones. Appropriate personal protective equipment, e.g., safety goggles, gloves, etc., should be worn due to hazards that may be encountered while using portable power tools and hand tools. Safety requires that floors be kept as clean and dry as possible to prevent accidental slips with - or around - dangerous hand tools. Around flammable substances, sparks produced by iron and steel hand tools can be a dangerous ignition source. Where this hazard exists, sparkresistant tools made from brass, plastic, aluminum, or wood will provide for safety.

Power Tool Precautions.

Power tools can be hazardous when improperly used. There are several types of power tools, based on the power source they use: electric, pneumatic, liquid fuel, hydraulic and powder-actuated. Employees should be trained in the use of all tools - not just power tools. They should understand the potential hazards as well as the safety precautions to prevent those hazards from occurring.

The following general precautions should be observed by power tool users:

Never carry a tool by the cord or hose. Never yank the cord or the hose to disconnect it from the receptacle. Keep cords and hoses away from heat, oil, and sharp edges. Disconnect tools when not in use, before servicing, and when changing accessories such as blades, bits and cutters. All observers should be kept at a safe distance away from the work area. Secure work with clamps or a vice, freeing both hands to operate the tool. Avoid accidental starting. The worker should not hold a finger on the switch button while carrying a plugged-in tool.

Tools should be maintained with care. They should be kept sharp and clean for the best performance. Follow instructions in the user's manual for lubricating and changing accessories. Be sure to keep good footing and maintain good balance. The proper apparel should be worn. Loose clothing, ties, or jewellery can become caught in moving parts. All portable electric tools that are damaged shall be removed from use and tagged "Do Not Use."

1.12

Machinery
BS EN 292 - Safety of machinery - Basic concepts, general principles for design is a standard which outlines all the basic principles including risk assessment, guarding, interlocking, emergency stops, trip devices, safety distances etc. (and much more). It refers to the other standards and also includes the essential safety requirements from the Machinery Directive.

Within BS EN 292, the main mechanical and non-mechanical hazards are:

Mechanical hazards can give rise to injury as a result of:

contact or entanglement with the machinery; trapping between the machine and any material or fixed structures; contact or entanglement with any material in motion; being struck by ejected parts of the machinery; being struck by material ejected from the machinery.

Basic machinery movement consists of rotary, sliding or reciprocation motion, or a combination of these.

These movements can cause injury by

entanglement, friction or abrasion, cutting, shearing, stabbing or puncture, impact, crushing, or by drawing a person into a position where one or more of these injuries can occur.

Contact or entanglement: Entanglement can occur from "drawing in" hazards between two parts rotating in opposite directions, or from contact with singly rotating surfaces (e.g. a drill bit). Cutting hazards Are created by all kinds of cutting tools such as milling cutters, circular saws, band saws, grinding machines or by the sharp edges of moving materials. Impact Injuries are caused when parts of machinery in motion hit a body but do not cause any penetrating injury. Crushing Occurs when a part of the body is caught between a moving part of a machine and a static part or a nearby solid structure. Drawing in hazards: Shearing or crushing injuries can occur when a part of the body is drawn into an in-running nip, such as a V-belt and pulley or chain and sprocket. Nips are also formed between counter-rotating drums or rollers, between material wound onto a drum or by material passing over roller conveyors. Non-mechanical hazards: The use of machinery will also expose the operator to hazards other than those due to the mechanical actions of the machine. These can be activities associated with the

task or incidental environmental conditions and include the following:

From falling or moving objects caused by insecure storage and poor handling of materials. From obstructions caused by poor storage and overcrowding. Due to poor handling and lifting facilities. From electricity (including static electricity), causing shock or burns. From chemicals or substances that may be toxic, irritant, flammable, corrosive or explosive. Due to fire. Due to noise leading to loss of hearing, tiredness, interference with speech communication. From extremes of temperature causing burns or scalds or health damaging effects caused by a hot or cold work environment. Due to mists, dusts and fumes that can cause illhealth or disease. From working conditions produced by poor lighting. Due to poor ergonomic design, leading to longterm musculo-skeletal problems.

It is important to remember that minor hazards which pose little risk in isolation can become a major risk when combined with other hazards.

1.13

The hazards presented by a range of equipment

The following chart is a summary of the main hazards associated with various workplace equipment. EQUIPMENT Abrasive wheels MAIN HAZARDS Friction/abrasion, ejection, entanglement.

Cement mixer Circular saw Compactor Conveyor systems Cylinder mower Drill Guillotine Lathes Paper shredder Photocopier Portable power tools Presses Simple robots Strimmer

Entanglement, traps. Cutting/severing. Drawing-in. Entanglement nips/traps. Entanglement, ejection, sharps. Puncture, entanglement. Shearing. Entanglement, ejection. Entanglement, cutting. Electrical, burns, nips, entanglement. Depends upon the power tool and its power source. Crushing, shearing. Impact/crushing. Ejection, entanglement.

A hazard/s associated with a Photocopier may include

1. 2. 3. 4.

? ? ? ?

entanglement electrical all of these nips

Work Equipment Congratulations - end of lesson reached