Unit 12 Work Equipement

8/3/2019 Unit 12 Work Equipement

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1.0Unit 12:Work equipment

hazards and control


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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 (ILOCode of Practice), ILO.

Tuition time: 7 hours.


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1.2

Introduction to Work equipment hazards and control

The purpose of this unit is to provide discussion, assistance and guidance for the safety ofmachinery, 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 ofinter-connected machines;

mobile work equipment such as lawn mowers, dumper trucks, road

sweepers, tractors; and motor vehicles (vans, mini-buses); andtowed 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, theladder 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.


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Use can be defined as "any activity involvingwork equipment and includes starting, stopping,

programming, setting, transporting (used for),repairing, modifying, maintaining, servicing and

cleaning"

Work Equipment can be defined as "anymachinery, appliance, apparatus, tool orinstallation 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


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1.3 The Supply of Machinery (Safety) Regulations 2008

RRRRegulations governing the supply of machinery werefirst enacted in 1992 and subsequently amended in 1994. In2006, a new EUDirective made amendments to theregulations and this Directive was adopted into British law inDecember 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 intendedto 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 whichare joined together for a specificapplication;

(ii) an assembly as referred to in sub-paragraph (i), missing only thecomponents to connect it on site or to

sources of energy and motion;

(iii) an assembly as referred to in sub-paragraph (i) or (ii), ready to be installedand able to function as it stands only ifmounted on a means of transport, or


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installed in a building or structure;

(iv) assemblies of machinery as referred to insub-paragraphs (i), (ii) and (iii) or partlycompleted machinery, which, in order to

achieve the same end, are arranged andcontrolled so that they function as anintegral whole;

(v) an assembly of linked parts orcomponents, at least one of which movesand which are joined together, intendedfor lifting loads and whose onlypower

source is directly applied human effort;

(b) interchangeable equipment described as;devices which, after the putting intoservice of machinery or of a tractor, areassembled with that machinery or tractorby operators themselves in order tochange its function or attribute a newfunction, in so far as they are not tools.

(c) safetycomponents described ascomponents;

(i) which serve to fulfil a safetyfunction;

(ii) which are independentlyplaced on the market;

(iii) the failure or malfunction ofwhich endangers the safetyofpersons; and


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(iv) which are not necessary inorder for the machinery to function,or

for which other components which

do not fall within the previous sub-paragraphs may be substituted inorder for the machinery to function;As noted above, the definition ofsafetycomponents is now backed upin the 2008 Regulations by anindicative list of examples ofproducts that fit this definition (seeAnnex E).

(d) lifting accessories described ascomponents or equipment that;

(i) are not attached to liftingmachinery;(ii) allow a load to be held;(iii) are placed between the

machinery and the load or on theload itself, or are intended toconstitute an integral part of theload; and(iv) are independently placed onthe market

(e) chains, ropes and webbing

described as being;designed and constructed for liftingpurposes as part of liftingmachinery or lifting accessories

(f) removable mechanical transmissiondevices described as;


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Removable components fortransmitting power between self-propelled machinery or a tractor andanother machine by joining them atthe first fixed bearing (when such

components are placed on themarket with a guard thecomponents and the guard togethershall be regarded as one product).

(g) partly completed machinerydescribed as;drive systems and other assemblies

which -

(a) are almost machinery;

(b) cannot in themselvesperform a specific application;and

(c) are only intended to beincorporated into or assembledwith other machinery or otherpartly completed machinery orequipment, thereby formingmachinery.


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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 thanthe 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 notcomply 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 safetymeasures to ensure that it does not kill or injure any person.

General requirements

The Regulations make it an offence for a responsible person to supplymachinery, 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, Declarationof Incorporation as appropriate, is CE marked and is in fact safe (see

Annex A).


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How to comply with the Regulations

Overview of conformity assessment procedures

The responsibility for demonstrating that machinery complies with theDirective 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 assessmentunder these Regulations with the choice of methodavailable to the responsible person being dependentfor the most part on whether the machinery inquestion falls within Annex D.

Thus for machinery:

- not included in Annex D, or included in it butmanufactured wholly in accordance withtransposed harmonised standards (see AnnexA), see method 1

- included in Annex D but either notmanufactured wholly in conformity with

transposed harmonised standards or wasmanufactured to be in conformity by notopting to use method 1, see method 2

- included in Annex D and manufacturedusing a Full QualityAssurance system, seemethod 3.


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Method 1Method 1Method 1Method 1 ---- Self AssessmentSelf AssessmentSelf AssessmentSelf AssessmentA responsible person, applying the general

principles (see page 14) and having regard tostandards (see page 10), undertakes a riskassessment against the Essential Health and SafetyRequirements (EHSRs - see Schedule 2, Part 1 ofthe Regulations), produces a technical file havingapplied 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 isintended for incorporation into other machinery orassembly with other machinery to constitute

machinery covered by the Regulations, theresponsible person must draw up a Declaration ofIncorporation for each machine (see Annex H) inthis case the partly complete machine must NOT beCE marked.

This option is not available for interchangeableequipment modifying the function of the machine or

machinery which can function independently.


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- EC Type examination

Where a responsible person makes a productwhich is not manufactured wholly in accordancewith transposed harmonised standards, i.e. theyhave not been published in the OJ (see Sources ofReference) they will be required to have it assessedby a Notified Body (see Annex A). If compliant theNotified Body will issue an EC-type examinationcertificate (see Annex I). This method is also anoption open to a manufacturer for machinery that iswholly manufactured to a harmonised standard.

Method 3 - Full QualityAssuranceA responsible person, having manufactured a

product using a full qualitycontrolsystem, has thatsystem assessed by a NB which has been accreditedfor this type of activity by UKAS. The NB willarrange the issue of the necessary documentationand CE marking (see Annex J).


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The marking is as illustrated in diagram 1,below. Except for small-scale machinery, the

marking may not be smaller than 5 mm in itsvertical height.

CE marking must be affixed in a distinct,visible, legible and indelible manner.The CE marking should not be affixed tomachinery for which a declaration ofincorporation has been issued.

The Regulations make it an offence to affix amark to machinery which may be confusedwith CE marking.

Machinery or safetycomponents that complywith the Regulations may also be subject toother Community Directives. For example, anelectric machine permanently installed in abuilding would need to comply with legislationimplementing the Construction Products andElectromagnetic Compatibility Directives aswell as any other existing relevant legislation.In such cases the CE marking indicates thatthe requirements of those other Directiveshave also been complied with.

Machinery bearing CE marking andaccompanied by the EC declaration ofconformitycan be presumed to satisfy theprovisions of the MachineryDirective unlessthere are reasonable grounds for suspectingotherwise.


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A person who either supplies machinery whichdoes not bear CE marking, or does so butthere is doubt as to validity is required, ifrequested by an enforcement authorityfromanyEU Member State, to provide any availableinformation that will allow it to determine its

compliance. Failure to supply suchinformation could, as a minimum, lead torestrictions being placed on its use which, inturn, could also lead to criminal prosecution.

The conformity assessment mechanismsavailable are shown in diagrammatic form inAnnex K.

Because partly completed machinery is onlyintended to be incorporated into or assembledwith other machinery, or partly completedmachinery, it should not be CE marked.Instead the responsible person shouldcomplete a Declaration of Incorporation (seeAnnex H). It is for the responsible person to CEmark the whole product at the point when it isplaced on the market/put into service - theDeclaration of Incorporation forming part ofthe technical file.


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The Directive amends the Lifts Directive 95/16/EC, and now regulatesconstruction site hoists, and lifts with a travel speed no greater than

0.15m/s.

Portable cartridge-operated fixing and other impact machinery are nolonger 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 theEHSRs.

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 affectmachine design including requirements for guarding and control systems.

The supplementaryEHSR'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 specialprocedures must be applied (Annex IV) but, significantly, the necessity to

involve a Notified

Body has been removed if the machinery is manufactured in accordancewith harmonised standards.


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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 andreviewed 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 whichmay be confused with CE marking.


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Machinery or safety components that comply with the Regulations mayalso 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 ElectromagneticCompatibility 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 ofconformity 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, itshould not be CE marked. Instead the responsible person should complete

a Declaration of Incorporation (see Annex H). It is for the responsibleperson 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 ofthe technical file.

.


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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 ofaccident throughout the foreseeable lifetime of

the machinery, including the phases of assembly and dismantling, even whererisks ofaccident 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 isinherently safe in use);

(b) control risks which cannot be eliminated by use ofappropriate safety measures;

(c) inform users of risks which cannot be totally eliminated

and indicate whether any particular training or Personal

Protective Equipment (PPE) is required.

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 prohibitany 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 byapplication ofsound ergonomic principles.

The design should also take into account the physical restraints placed on the

operator by use ofPPE. Any "essential special equipment and accessories" mustbe supplied so that the machinery can be safely and properly adjusted, maintained

and used.


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It is also essential that neither the materials used in machinery construction northe 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) whichwill bring it safely to a complete halt.

Each machine must be fitted with one or more emergency stop devices to avertany 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 alsoindicate which parts of the machinery are subject to wear and give details of the

criteria for any replacement.


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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 thedanger zone."

2. Fixed guards must be securely held in place by a system that can only be

opened using the appropriate tools.

3. 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.

4. Type B movable guards must be incorporated into the controlsystem so

that moving parts cannot start while they are still accessible and that theycannot 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.

5. Adjustable guards restrict access to moving parts where operatorintervention is necessary. They must be easily adjustable, either manually

or automatically, without the use of tools.

6. Protection devices must be incorporated into the controlsystem 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 eitherprevent the machine from starting or immediately stop its moving parts.


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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 designedso 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 aminimum and that it is safe. Cleaning internal parts of machinery should be possible

without having to go inside it.


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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 arenot obvious, e.g. electrical, radioactivity or pressure in hydraulic systems.

Warnings should also be issued in the language of the country in which themachinery 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 ofnoise 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 ofeducation/expertise thatcan 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 machineryposing special hazards.


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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 inconcentration can cause an accident. Highly-skilled

workers can be prone to errors of this type.

2. Mistaken actions. Performing a wrong

action whilst under the impression that it is the rightone.

3. Misperceptions. These tend to occur under

stress when a mass of information competes for anindividual's attention or when a pre-conceived idea

blocks out other information. This often occurs

where the individual does not fully understand theprocess.

4. Mistaken priorities. These errors are usually

the result of a conflict of priorities within anorganisation, when other factors can sometimes take

precedence over safety arrangements.

5. Wilful actions. Usually, accidents whichoccur 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.


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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 ofriskcontrol.

Operators have a responsibility for their own safety and that of others whomay 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 reductionwhen 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 concealhazardous 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 additionalphysical safeguarding, personal protective equipment or systems of work.

It is well-known that a substantial number of fatal accidents occur duringmaintenance operations.


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Maintenance personnel must be trained for the tasks they are expected toperform, 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 whenmaintenance 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 wheremachinery 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 undergoperiodic testing and/or inspection.

The proper management ofmaintenance is often neglected, resulting inequipment 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 expenditurecan 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 andequipment, 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 stockcontrol for spare parts.

When equipment is reliable, it is more likely to be safe. Unexpectedequipment 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


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period of early failures followed by an extended period of random failuresending 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 poormaintenance.

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 likelyto be, so that maintenance tasks can be tailored accordingly.

Manufacturers of equipment will have prepared their maintenanceprogrammes 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 maintenancepersonnel.

The failure of protective safety devices may not have a direct effect on theoperational functions of a plant and may remain unnoticed until their non-

function is combined with another failure, thus creating a primary hazard.

Proper maintenance ofsafety 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 onewill 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 ofautomatic and continuous computer data evaluations.

Failure of operational equipment will certainly lead to some economicloss, 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 arereplaced or repaired before failure can occur.

Where high standards ofreliability 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 allhave a significantly negative influence on safe and reliable operation.


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Employers must ensure that there is relevant training and instruction ofoperators, 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 beappropriate 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.

2. Scheduled or routine maintenance consists of:

(a) cleaning;

(b) adjustment;

(c) lubrication;

(d) inspection and testing.

This is probably the most common form ofmaintenance 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 periodicreplacement of wearing parts prior to failure, based on known past failure

history.

4. Predictive maintenance is based on a monitoring system to detect

deterioration in components so that these can be replaced before failureoccurs. This can be more economical on costly complex plant than

preventative maintenance because components are only replaced when


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needed and not on a time-based schedule. Monitoring systems usuallymeasure physical properties such as vibration and temperature.

5. Improvement maintenanceis aimed at reducing or avoidingmaintenance tasks by eliminating problems at source by a process of re-

design 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 themaintenance 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 onwhat 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 besubject to test and inspection of varying intervals depending on use.

For instance, hire equipment should be tested and inspected before each hire, anddouble-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.


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1.8.1 Examination Schedules

Type of Plant, Machinery and Equipment ConstructionSites

Education OfficeBuildings

Theatres &Cinemas

Steam Boilers and steam

ovens

14 14 14

Steam Pressure Plant 26 26 26

Hot Water Boilers (>100oC) 14 14 14

Air Pressure Plant 26 26 26 26

AirConditioning/RefrigerationPlant (>25kW)

26 26 26

Pressure

Systems

Other Pressure Systems 26 26 26 26

Passenger Lifts 6 6 6 6

Other Equipment which canbe used to lift persons

6 6 6 6

Cranes 12 12 12 12

Other Lifting Equipment 12 12 12 12

LiftingEquipment

Lifting Accessories (Tackle) 6 6 6 6

Power Presses and PressBrakes

6 6 6 6

Other Power Presses 6 6 6 6

Guillotines (Printing Works) 6 6 6 6

Guillotines (Factories) 12 12 12 12

Injection MouldingMachines

12 12 12 12

ProcessMachinery

Guarded Processmachinery

12 12 12 12

Electrical Installations andEquipment

* * * 12Electrical

Portable ElectricalAppliances

*


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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 capableof starting up unexpectedly and should have one or more emergency stop

devices fitted.

Consideration must be given to complex installations where processesupstream 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 stopthe machine. It may operate directly but is more often a part of a control

system incorporating sensors, limit devices, brakes, clutches and othercomponents.

A control may consist of nothing more than a simple on/off switch. Newequipment will probably be supplied with appropriate controls; machines

consisting of linked sub-assemblies may need a systematicrisk assessment

to determine the best positions for controls. The development of

programmable electronic systems has brought new and less obvious risksinto 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 theiroperation should not increase the risk ofinjury from another source.

Operators should have a clear view from the control position so that no-one 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. Startcontrols and other functional controls should be constructed andpositioned 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 ofpower after a power failure. Astop control should be sited near every start control.

Controls must be clearly identifiable and easily distinguishable from eachother by positioning, shape, colour, size or labelling and their movement


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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 machinebehaviour. They must be chosen to

withstand all stresses associated with the use of the equipment. Thisincludes environmental stresses due to impacts, vibration, temperature,

moisture, corrosive substances, magnetic and electric interference. Incritical 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 theprotective function.

On certain installations, where the start control is in such a position inrelation 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 displayedmust 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 well-

known lightning flash denoting electrical hazards). High visibility paint

can also draw attention to a hazard.


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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 theoperator as they perform certain tasks? Is there local lighting fitted to theequipment 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 therotation 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 thehealth and safety at work of themselves and any other people who might

be affected by their acts or omissions and to co-operate with theiremployers and others to enable them to comply with statutory duties andrequirements.

Additionally, they must not intentionally or recklessly misuse or interferewith 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 anexperienced operator as well as to a careless worker or a novice.

As no safety mechanism is absolutely secure against deliberate misuse orignorance, 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, task-

related or health and safety awareness. This record should contain detailsoftraining received, including refresher training where applicable.


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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 providespecific training, such as in the case of the mounting of abrasive wheels.

The following should also be considered in order to ensure that machineryis 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 toenable:

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 andinternal 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.


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1.11 Hand and Power Tools

Tools are such a common part of our lives that it is difficult to rememberthat they may pose hazards.

All tools are manufactured with safety in mind but, tragically, a seriousaccident 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 thescrewdriver to break and fly, hitting the user or other

employees.

If a wooden handle on a tool such as a hammer or an axe isloose, 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 properlyusing and maintaining tools.

Employers should caution employees that saw blades, knives, or other

tools be directed away from aisle areas and other employees working


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in proximity. Knives and scissors must be sharp. Dull tools can be morehazardous 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 preventaccidental 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, spark-resistant 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 ofpower 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 safetyprecautions 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 thereceptacle.

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 tooperate the tool.

Avoid accidental starting. The worker should not hold a finger

on the switch button while carrying a plugged-in tool.


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Tools should be maintained with care. They should be keptsharp 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 andalso includes the essential safety requirements from the Machinery

Directive.

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

are:

Mechanical hazardscan 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.


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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 whereone 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 fromcontact with singly rotating surfaces (e.g. a drill bit).

Cutting hazards

Are created by all kinds of cutting tools such as millingcutters, 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 movingpart 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 woundonto a drum or by material passing over roller conveyors.

Non-mechanical hazards:

The use of machinery will also expose the operator tohazards other than those due to the mechanical actions of

the machine. These can be activities associated with the


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task or incidental environmental conditions and include thefollowing:

From falling or moving objects caused byinsecure storage and poor handling of materials.

From obstructions caused by poor storage andovercrowding.

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 orscalds or health damaging effects caused by ahot or cold workenvironment.

Due to mists, dusts and fumes that can cause ill-

health or disease.

From working conditions produced by poor

lighting.

Due to poor ergonomic design, leading to long-term 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.


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1.13 The hazards presented by a range of equipment

The following chart is a summary of the main hazards associated with various workplaceequipment.

EQUIPMENT MAIN HAZARDS

Abrasive wheels Friction/abrasion, ejection, entanglement.

Cement mixer Entanglement, traps.

Circular saw Cutting/severing.

Compactor Drawing-in.

Conveyor systems Entanglement nips/traps.

Cylinder mower Entanglement, ejection, sharps.Drill Puncture, entanglement.

Guillotine Shearing.

Lathes Entanglement, ejection.

Paper shredder Entanglement, cutting.

Photocopier Electrical, burns, nips, entanglement.

Portable power tools Depends upon the power tool and its power source.

Presses Crushing, shearing.

Simple robots Impact/crushing.Strimmer E jection, entanglement.

A hazard/s associated with a Photocopier may include

1. ? entanglement2. ? electrical3. ? all of these

4. ? nips

Work Equipment

Congratulations - end of lesson reached


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Documents

Unit 12 Work Equipement