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Transcript of Guide to Safeguarding Common Machinery and · PDF fileGuide to safeguarding common machinery...
Guide to safeguarding common machinery and plant
Workplace Health and Safety Queensland
csq/05/2432
Workplace Health and Safety QueenslandTelephone: 1300369915Website: www.dir.qld.gov.au
ThinkSafe–Work Smart
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland �
Contents
Section 1 – What is machinery and plant? 5
Section 2 – The risk management process 5
2.� Identifyingmachineryorplanthazards 5
2.2 Assessingtheriskofidentifiedhazards 9
2.3 Decidingoncontrolmeasures �0
2.4 Implementingcontrolmeasures �2
2.5 Monitoringandreviewingeffectivenessofcontrolmeasures �3
2.6 Keepingdocumentationandrecords �3
Section 3 – Guard design 18
3.� Typesofguards �8
3.�.� Fixedguards �8
3.�.2Interlockingguards �8
3.�.3Automaticguards �9
3.�.4Distanceguards 20
3.�.5Tripguards 20
3.2 Basicrulesforguarddesign 2�
3.3 Servicingconsiderations 2�
3.4 Ergonomicconsiderations 2�
3.4.�Reachmeasurements 2�
3.4.2Guardplacement 22
Section 4 – Guards for different machine types 24
4.� Exposedrotatingcuttingprocesses 24
4.2 Pulleysanddrives 24
4.3 Rotatingshaftsandrollers 25
4.4 Safetydevices 25
4.5 Combinationofguardingandsafetydevices 26
4.6 Safeworkrulesandpractices 26
4.6.�Isolation 26
4.6.2Emergencystopdevices 26
4.6.3Inspection,cleaning,repair,maintenanceandemergencyprocedures 27
4.6.4Openingandremovingguards 27
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland2
4.6.5Weight 27
4.6.6Interactions 27
4.6.7Colourcoding 27
Section 5 – Safeguarding of power presses, conveyors and robotics 28
5.� Powerstampingpresses 28
5.�.�Hazardsandrisks 28
5.�.2Controlmeasures 28
5.2 Pressbrakes(mechanicalandhydraulic) 30
5.2.�Hazardsandrisks 30
5.2.2Controlmeasures 30
5.3 Conveyors(bulkhandling) 3�
5.3.�Hazardsandrisks 3�
5.3.2Controlmeasures 3�
5.4 Robotics 33
5.4.�Hazardsandrisks 33
5.4.2Controlmeasures 34
Section 6 – Other machinery safety issues 37
6.� Workorganisation 37
6.�.�Layout 37
6.�.2Housekeeping 37
6.�.3Workpractices 38
6.2 Workenvironment 38
6.2.�Dust 38
6.2.2Lighting 38
6.2.3Noise 39
6.2.4Hotandcoldenvironments 39
6.2.5Ventilation 39
6.2.6Confinedspaces 40
6.2.7Electricalsafety 40
6.3 Minimisinghumanerror 40
6.4 Registrableplant 42
6.5 Registrableplantdesign 42
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland 3
Section 7 – Further information 43
7.� StandardsAustralia 43
7.2 Consultingengineers 43
7.3 Workers 43
7.4 Industryassociationsandsimilarworkplaces 43
7.5 WorkplaceHealthandSafetyQueensland 43
Appendix 1 – Machinery and plant hazard list 44
Appendix 2 – Dictionary of defined terms 47
Appendix 3 – Risk Assessment Form 50
Appendix 4 – Risk Assessment Template 52
Appendix 5 – Australian Standards 53
Disclaimer
TheinformationprovidedinthispublicationisdistributedbytheQueenslandGovernmentasaninformationsourceonly.
Theinformationisprovidedsolelyonthebasisthatreaderswillberesponsibleformakingtheirownassessmentofthemattersdiscussedhereinandareadvisedtoverifyallrelevantrepresentations,statementsandinformation.
ForspecificinformationonmattersdiscussedinthispublicationpleaserefertotheWorkplace Health and Safety Act 1995.
©TheStateofQueensland(DepartmentofIndustrialRelations)
April2006
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland4
PurposeThe Guide to safeguarding common machinery and planthasbeendevelopedtohelppeopleconductingabusinessorundertaking(includingemployersandself-employedpeople)andworkerstoensurecommonmachineryandplantintheworkplaceissafeandwithoutrisktohealthandsafety.
Thisguideraisesawarenessofarangeofhazardsassociatedwithcommonmachineryandplant,aswellasrisksthatmayresultfromthesetypesofhazards.Practicaladviceisprovidedinrelationtothemethodsthatcanbeusedtosafeguardcommonmachineryandplantintheworkplace,andadviceonhowtoselectandimplementtheappropriatesafeguards.
Thisisachievedbyusingariskmanagementapproachwherebyhazardsareidentified,thedegreeofriskofeachhazardisassessed,controlmeasuresareidentifiedandimplementedandfinally,monitoringandreviewoftheeffectivenessofthechosencontrolmeasuresisperformed.
Itshouldbenotedthattheinformationcontainedinthisdocumentisintendedforguidanceonly,andthattheremaybeadditionalhazardsandsubsequentrisksatyourworkplacewhichhavenotbeenspecificallyaddressedinthisguide.YouarestillrequiredundertheWorkplace Health and Safety Act 1995toidentifyandassesstheserisksandensurethatappropriatecontrolmeasuresareimplementedandreviewedtopreventorminimiseexposuretotheserisks.
Note: This guide should be read in conjunction with the primary source document, the Plant Code of Practice 2005. In addition to this, other important documents that should also be read in conjunction with this guide are the Workplace Health and Safety Act 1995, Risk Management Advisory Standard 2000, Australian Standard 4024.1 – 1996 Safeguarding of machinery - General principles, other Australian Standards as identified in Appendix 5 and relevant manufacturer’s instructions and operator’s instructions/manuals.
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland 5
Section 1 – What is machinery and plant?Machineryisacollectivetermformachinesandtheirparts.Amachineisconsideredtobeanyapparatusthathasinterrelatedpartsandisusedtoperformwork.
Planthasabroadermeaningandincludesmachinery.Otheritemsofcommonplantintheworkplaceincludeequipment,implementsandtools.Fittings,connectionsandaccessoriesarealsoconsideredtobeplant.
Thisguidefocusesontheguardingofmachinerycommonlyfoundinworkplaces,butalsoconsidersotheritemsofplant.Toremindreadersofthis,theguidediscussesmachineryandplanttogether.
Section 2 – The risk management processThehazardsassociatedwithoperatingcommonmachineryandplantarenotalwaysobvious,andtherearegenerallyanumberofelementsthatwillaffectsafeoperation.Theriskmanagementapproachwillhelpyoumakeajudgmentabouttherisksassociatedwiththesehazardsandimplementappropriatecontrolmeasures.
TheriskmanagementapproachisoutlinedundertheWorkplace Health and Safety Act 1995andinvolves:
�. identifyinghazards2.assessingrisksthatmayresultbecauseofthehazards3.decidingonappropriatecontrolmeasurestopreventorminimisetheleveloftherisks4. implementingthechosencontrolmeasures5.monitoringandreviewingtheeffectivenessofthechosencontrolmeasures.
Thesefivestepsarecommonlyknownastheriskmanagementprocess.ThisprocessisoutlinedcomprehensivelyintheRisk Management Advisory Standard 2000.
2.1 Identifying machinery or plant hazardsThefirststepinassessingtherisksassociatedwithmachineryandplantistoidentifyallitemsofplantusedintheworkplace.Aninspectionoftheworkplaceshouldbecarriedoutlookingforanyoftheseitems.Thedesiredoutcomeofthisstepisalistofallitemsofmachineryandplantthatposepotentialhazards.
Thehazardsassociatedwithmachineryandplantincludemechanical,biological,chemical,psychologicalandergonomichazards.Mechanicalhazardsareamajorcauseofinjuryassociatedwiththeoperation,maintenanceandrepairofmachineryandplant.Mechanicalhazardsincludecuttingandsevering,crushing,shearing,impactandentanglement.
Startbyidentifyingallmachineryandplantoperatedattheworkplaceandassociatedwithanyworkperformed.Includecommonitemsthatposepotentialhazardsthatmaynotnormallybethoughtofas‘machines’orplant.Theseitemsmayincludeofficemachines,suchaspaperguillotinesandautomaticstaplers.
Checkbothinsideandoutsidetheworkenvironmentformachineryandplantthatmayposearisktopeopleintheworkplace(e.g.garbagecompactorsoperatedoutside).Ifworkisnormallydoneatotherlocations,mobileplantandtoolsusedattheselocationsshouldalsobeincluded.
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland6
Onceallmachineryandplanthasbeenidentified,thehazardsassociatedwiththeseitemscanbeidentified.Critically inspect each piece of machinery and plant and the way it is operated to identify any parts, processes or operating procedures that may cause harm.
Amethodofidentifyingmachineryandplanthazardsistoconsiderthefollowingfactors:
• tasks(operating,cleaning,adjusting,setting-up,maintaining,repairingorworkingonamachine,e.g.powerpress,foodslicer)—considerallactivitiesthattakeplace
• locations(proximitytoothermachinesandworkprocesses,fixedplant,portableplantandtools)• installationofplant(safeandcorrectinstallation)• productionprocesses(forming,finishing)• useofmobileplantatotherlocations• safetransportationofmobileplant.
Byconsideringthesefactors,thefullrangeofhazardsassociatedwiththemachineryorplantcanbeidentified.
Wheremachineryandplanthazardsarenotimmediatelyobvious,therearemanyotheractivitiesthatcanbeundertakentohelpidentifythem.Theseinclude:
• testing,particularlyofplantandotherequipmentandnoiselevels• scientificortechnicalevaluation• analysingrecordsanddataincludingworkers’compensationclaims,incidentsandnearmisses,
workercomplaints,sickleaveandstaffturnover• acquiringinformationfromdesigners,manufacturers,suppliers• acquiringinformationfromotherorganisationssuchasunions,employerbodies,occupational
healthandsafetyconsultants• environmentalandmedicalmonitoring• undertakingworkersurveys.
Examining the activities performed at the workplace and the related danger zones (such as moving parts) of plant and machinery will assist in identifying hazards.Thesehazardsmayinclude,butarenotlimitedtothoseillustratedbelow.
These machines and items of plant are shown in their unguarded state to demonstrate the hazards and danger zones.
Illustration 1-drawinginpointsbetweentwocounter-rotatingparts
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland 7
Illustration 2–in-runningnippointsbetweenrotatingandtangentiallymovingsurfaces
Illustration 3-shearpointsbetweenamachinerypartandaworkpiece
Illustration 4-cuttingareasonabandsaw
Illustration 5-impactandcrushingareas
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland8
Illustration 6-entanglementcausedbycontactwithasinglerotatingsurface
Illustration 7-stabbingpointscausedbymovingpartsofmachineryormaterial
Illustration 8-abrasionareas Illustration 9-flyingparticles
Illustration 10-protrusionscancauseinjuryfromentanglement
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland 9
Manyofthetypesofhazardsillustratedcanusuallybeeffectivelymanagedbytheinstallationofphysicalbarriers.Examplesofwaystocontrolthesehazardsareaddressedinsection3(Guarddesign)andsection4(Guardsfordifferentmachinetypes).
Beforeproceedingtothenextstepofassessingrisk,youshouldidentifyifthehazardsareissuesaboutwhichthereisaregulationorcodeofpractice(madeundertheWorkplace Health and Safety Act 1995)orguidancematerial(producedbyWorkplaceHealthandSafetyQueensland).TheCode of Practice for Plant 2005 alsoencouragespeopletoconsultarangeofAustralianStandardsandoverseasstandardstoassistintheprocessofensuringmachinesafetyandsafeoperation.
Itisalsoimportanttoconsiderthatthereareotherspecifichazardsassociatedwithmachineryandplantthatarenotassociatedwiththeactualmechanicaloperation.Therisksassociatedwiththesehazardsshouldalsobeidentified,assessedandmanaged.Theserisksinclude:
• releaseofsubstances—machineryorprocessesmayreleaseorproducesubstancesormaterials,maybeasaby-product,whichishazardous.Examplesincludefumes,chemicalsandmetalfilings
• noise—noiselevelsmaychangeatdifferentstagesofuse• hotorcoldmachineryorplantparts—sourcesofheatcanincludefriction,moltenmaterial,hot
metalshavings,hotgases,nakedflames,radiantheat.
Section6(Othermachinerysafetyissues)providesmoreinformationinrelationtothesespecificissues.
2.2 Assessing the risk of identified hazardsAriskassessmentseekstoprioritiseidentifiedhazardssothatrisksassociatedwitheachhazard(thosethathavethepotentialtocauseharm)canbeeliminatedorreduced.Identifiedhazardsareassessedtodeterminetheirrealpotentialtocauseinjury.
Whereahazardisidentified,anassessmentofrisksassociatedwiththehazardshouldbeundertaken.Separateriskassessmentsshouldbecarriedoutforeachmachineandanyassociatedsystemofworkusedwiththatmachine.Ifanyalterationormodificationismadetothemachine,ariskassessmentshouldberepeated.
Therearethreestepsinassessingrisks:
Step�Foreachhazard,estimatethelikelihoodofanincidentoraccidentoccurringattheworkplaceorwhileconductingtheworkactivity.Existingcontrolmeasuresshouldbeconsideredseparately,astheymaynotnecessarilycontroltherisk,butcreateadditionalhazards.
Step2Foreachhazard,estimatetheconsequencesofanincidentoraccidentoccurringattheworkplaceorwhileconductingtheworkactivity.Existingcontrolmeasuresshouldbeconsideredseparately,astheymaynotnecessarilycontroltherisk,butcreateadditionalhazards.
Step3Combinetheseestimatesoflikelihoodandconsequencetodetermineariskratingforeachhazard.ThiscanbeeasilyreadfromtheRiskAssessmentPriorityChart.Thischartrankstherisksintermsoftheirpriorities.
ForexampleifthepossibilityofinjuryfromaparticularitemofplantormachineryplantisPOSSIBLE(couldhappen,butrarely)andtheconsequencesofsuchaninjuryareMAJOR(seriousinjuries),thentheriskscoreis4.
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland�0
Risk Assessment Priority Chart
Likelihood: ProbabilityHowlikelythatitcouldhappen?
Consequences:Howseverelycouldithurtsomeone?
EXTREMEdeath, permanent disablementcatastrophickills,disables,permanentinjury
MAJORserious bodily injurymajorsignificantinjury,notpermanent
MODERATEcasualty treatmentminorfirstaidonly,nolosttime
MINORfirst aid only, no lost time
Very likelyCouldhappenfrequently
� 2 3 4
LikelyCouldhappenoccasionally
2 3 4 5
PossibleCouldhappenbutrarely
3 4 5 6
UnlikelyCouldhappen,probablyneverwill
4 5 6 7
Thefollowingscoresindicatehowimportantitistodosomethingabouteachrisk:
Score Action
�,2or3 Dosomethingabouttheserisksimmediately
4or5 Dosomethingabouttheserisksassoonaspossible
6or7 Theserisksmaynotneedimmediateattention
Onceeachriskhasbeenrated,aprioritisedlistofworkplacerisksrequiringactioncanbedeveloped.
AtemplateforaRiskAssessmentFormisincludedinappendix3.Thiswillhelptoassesstherisksposedbymachinery.Thisformcanbephotocopiedasmanytimesasneeded.Itissuggestedthatoneformbeusedpermachine,orpartofamachineifthereareseveralhazards.Thisformmaybeadaptedforotherthingssuchaspurchase,installation,maintenanceandworkprocessesrelevanttomachinesintheworkplace.
2.3 Deciding on control measuresOnceeachhazardhasbeenrated,aprioritisedlistofworkplacerisksrequiringactioncanbedeveloped.TheRiskAssessmentForm(appendix3)willhelptoassesstherisksposedbymachinery.
Onceaprioritisedlisthasbeenmade,controlmeasurestoeliminateorreducetheassessedriskscanbedecidedon.Whereanassessmentidentifiesaneedtocontrolarisktohealthandsafety,
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland ��
thatriskshouldbeeliminated,orwhereitcannotbeeliminated,minimisedtoasafelevel.Controlmeasuresshouldbechosenfromthemostpreferredmethodtotheleastpreferredmethodbyusingthehierarchyofcontrol.
UndertheWorkplace Health and Safety Act 1995,apersonmustconsidertheappropriatenessofcontrolmeasuresinthefollowingorder:
A.eliminatethehazardorpreventtheriskB.ifeliminatingthehazardorpreventingtheriskisnotpossible,minimisetheriskbythecontrol
measureslistedbelow.Thesecontrolmeasuresmustbeconsideredinthefollowingorder:�. substitutethehazardwithahazardoflesserrisk2.isolatethehazardfromanyonewhomaybeatrisk3.minimisetheriskbyengineeringmeans4.applyadministrativemeasures5.usepersonalprotectiveequipment.
Thehierarchyofcontrolmeasuresisexplainedinmoredetailbelow.
Elimination—thisisthemosteffectivemethodofcontrolandshouldalwaysbeattemptedfirst.Forexample,discontinuedangerouspracticesorremoveordisposeofdangerousequipment.
When elimination is not practicable Eliminatingamachineorprocessfromyourworkplacemaynotalwaysbepracticable.Inthesesituationsthefollowingcontrolmeasuresshouldbeconsideredinthefollowingorder.
Substitution—replacingamaterialorprocessassociatedwithplantwithalesshazardousonewillreducerisk.Forexample,replaceanunstablepedestalfanwithawallorceilingmountedmodel,orusealesshazardousprocessorpartsuchasmouldedplasticprocessinsteadofpressedmetalmanufacturingprocess.
Isolation—isolating(orseparating)aprocessormachinefromworkerscanbeachievedbyeitherdistancingtheprocessormachinewiththerestoftheworkplace,orbyinsertingaphysicalbarrierbetweentheprocessormachineandworker.Forexample,installacousticboothsaroundnoisyequipmentoruseremotehandlingequipmentsuchasapush-stick.
Engineering—thedesign/redesignandinstallationofequipmenttocounteracthazardsareconsideredengineeringcontrols.Forexample,installanexhaustventilationsystemtoextractdangerousfumes,orredesignanelectricalsystemtoallowfortheinstallationofemergencystopbuttonswithineasyreachofoperatorsofmachineryorplant.
When exposure is not or cannot be minimised by other means?Controlbytheabovemeansisnotalwayspracticable.Evenwhereoneormoreoftheabovecontrolmeasureshasbeenimplemented,additionalcontrolmeasuresshouldbeconsidered.
Thefollowingmethodsshouldnotberelieduponastheprimarymeansofriskcontrol,untiltheabovecontrolshavebeenconsidered.Theyaredependentonhumanbehaviourandrequiremanagement,enforcementandcommitmenttoworkeffectively.Theymaybeusedasaninterimmeasureuntilhigherlevelcontrolsareimplemented.
Administration—administrationcontrolsareproceduresorinstructionsyoucanputinplacetominimiseexposuretoarisk.Thesecontrolscanincludethetimeofwork,hoursofwork,whodoestheworkandwhohasaccesstoworkareas,machineryorplant.Forexample,trainworkersintheproperproceduresandprocessesforoperatingmachineryorplant,andlimitexposuretoortheamountoftimespentdoinghazardousworkactivities.
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland�2
Personal protective equipment—personalprotectiveequipmentmeansclothing,equipmentorsubstanceswhich,whenworncorrectly,protectpartorallofthebodyfromrisksofinjuryordiseaseatworkorintheworkplace.Forexample,itincludesprotectiveeyewear,protectivehearingdevices,sturdyglovesormeshglovestopreventcuttinginjuries.Thecontrolofexposuretomachineryorplantrisksshouldbesecuredbyoneormoremeasuresotherthantheprovisionofpersonalprotectiveequipment.Useofpersonalprotectiveequipmentistheleasteffectivemethodofcontrollingrisk,althoughalong-termstrategyusingothermethodsmayrequiretheshort-termuseofpersonalprotectiveequipmenttoattainthisaim.Forexample,youmaydecidetoreplacenoisymachineryorplantwithaquieterversion.Intheinterim,protectivehearingdevicesareprovidedtoworkersexposedtothenoisymachineryorplant.
Topreventorminimiseexposuretoarisk,acombinationoftheabovemethodscanbeimplementedconcurrently.Forexample,acombinationofisolation,administrativeandpersonalprotectiveequipmentcontrolmeasurescanbeusedatthesametime.Byusingacombinationofcontrolmeasures,riskisreducedfurtherandthereislessrelianceonasinglecontrolmeasureshoulditfail.
Thechosenmethodofcontrollingtheriskshouldberecorded.AsampleformatofrecordingcontrolmeasurescanbefoundintheRisk Assessment Form(appendix3).Ifthepreferredcontrolmeasurecannotbeimplementedimmediately,theformcanbeusedtonotethecontrolsintendedtobeusedimmediatelyasashort-termsolution,andwhatisintendedtobedonelaterasalong-termsolution.Implementationtimeframesshouldberecordedandthedocumentreviewedregularly.
2.4 Implementing control measuresTheselectedcontrolmeasuresneedtobeimplementedformachineryorplantrequiringsafeguardingtoensurethereisnorisktoworkersorothers.Thismeansundertakingthoseactivitiesnecessarytoallowthecontrolmeasurestofunctionoroperateeffectively.Implementingcontrolmeasuresinvolves:
• Developing work procedures Workproceduresshouldbedevelopedinrelationtothenewcontrolmeasurestoensuretheir
effectiveness.Management,supervisionandworkerresponsibilitiesneedtobeclearlydefinedintheworkprocedures.Inrelationtotheuseofmachineguarding,themanager’srolemayinvolveensuringtheappropriateguardingispurchasedandthatitisinstalledcorrectly.Thesupervisor’srolemayinvolveensuringtheworkersoperatethemachineonlywiththeguardinginplace.Theroleofworkersmayinvolveusingthemachinewithguardinginplaceasinstructedorthemaintenanceofthemachineandguard.
• Communication Workersshouldbeinformedaboutthecontrolmeasurestobeimplemented.Itisimportantto
clearlycommunicatethereasonsforthechanges.Informationmayalsoneedtobeprovidedtootherswhomayentertheworkplace,includingcleaners,visitorsandcontractstaff.
• Providing training and instruction Trainingandinstructionshouldbeprovidedfortheworkers,supervisorsandothersinrelation
tothenewcontrolmeasures.Thismayincludesafeuseandoperationofguards,breakdownprocedures,andrepairandmaintenanceasappropriate.
• Supervision Adequatesupervisionshouldbeprovidedtoensurethatthecontrolmeasuresarebeingused
correctly.
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland �3
• Maintenance Maintenancerelatingtocontrolmeasuresisanimportantpartoftheimplementationprocess.
Workproceduresshouldclearlyidentifymaintenancerequirementstoensuretheongoingeffectivenessofthenewcontrolmeasures.
2.5 Monitoring and reviewing effectiveness of control measuresThefinalstepintheriskmanagementprocessistomonitorandreviewtheeffectivenessofcontrolmeasures.Forthisstep,itcanbeusefultoaskquestionssuchas:
• Havecontrolmeasuresbeenimplementedasplanned?• Arethesecontrolmeasuresbeingused,ifso,aretheybeingusedcorrectly?• Arecontrolmeasuresworking?• Havechangesmadetocontrolexposuretotheassessedrisksresultedinwhatwasintended?• Hasexposuretotheassessedrisksbeeneliminatedoradequatelyreduced?• Haveimplementedcontrolmeasuresresultedintheintroductionofanynewhazards?• Haveimplementedcontrolmeasuresresultedintheworseningofanyexistinghazards?
Inordertoanswerthesequestions,youcan:
• consultwithworkers,supervisorsandhealthandsafetyrepresentatives• measureexposure(e.g.takenoisemeasurementsinthecaseofisolationofanoisesource)• refertooccupationalhealthandsafetyconsultantsandrepresentativesofindustryassociations,
unionsandgovernmentbodies• refertomanufacturer’sinstructions• monitorincidentreports.
Youshouldsetadatetoreviewtheentireworkplacehealthandsafetyriskmanagementprocess.Reviewsshouldbeconductedatleastonceevery�2months,howevermayberequiredmorefrequentlydependingonindividualvariablesattheworkplace.Thefrequencyofreviewsshouldbedeterminedbytheriskmanagementprocess.
Riskmanagementisongoingandtheresultsofriskmanagementshouldbeupdated,whetherornottheprocessiscomplexandwhetherornottheresultsarerecorded.Theriskmanagementprocessshouldberepeatedatintervalsandwheneverthereisreasontosuspecttheresultsarenolongervalidbecause:
• newplantisintroduced• plantismodifiedsoitdeviatesfromtheoriginaldesign• thereisachangeinworkpracticesassociatedwithplant• thereisacomplaintfromworkers.
2.6 Keeping documentation and recordsAdequaterecordingoftheriskmanagementprocessundertakeninregardstoplantandmachinerywillhelpyoutodemonstratethatyouhavebeenactivelyworkingtoensureworkplacehealthandsafety,shouldyouneedtoprovethis.
Keepingrecordswillalsohelpyoukeeptrackofwhatyouhavedoneandareplanningtodo.Thisshouldmaximisetheeffectivenessoftheprocess.Atemplateforrecordingtheentireriskmanagementprocessisprovidedinappendix4.Thistemplatecanbephotocopiedasmanytimesasneeded.Itissuggestedthatoneformbeusedpermachine,orpartofamachineifthereareseveralhazards.ThistemplateshouldbeusedinconjunctionwiththeRiskAssessmentForm(appendix3).
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland�4
Thedetailandextentofrecordingwilldependonthesizeofyourworkplaceandthepotentialformajorworkplacehealthandsafetyissues.
Case studyThereareanumberofwaysinwhichtheriskmanagementprocesscanbecarriedout.Acasestudyhasbeenusedinthissectionoftheguidetodemonstrateonemethodofconductingtheriskmanagementprocess.Thiscasestudyassessestheriskfrommechanicaltypehazards,specificallycuttingandseveringhazardsassociatedwithusingamachiningcentre.
Amachiningcentreisanumericallycontrolledmachinetool,capableofperformingmultiplemachiningoperationsandabletochangetoolsautomaticallyfromamagazineorsimilarstorageunit.Theoperationsthatmaybeperformedincludemilling,boring,drilling,cuttingandtapping.
Itshouldbenotedthatcuttingandseveringhazardsarejustoneofthemanymechanicalhazardsassociatedwithmachineryandplant.Othermechanicalhazardsincludecrushing,shearing,impactandentanglement.Therearealsoothertypesofhazards,otherthanmechanicalhazards,whichareassociatedwithmachineryandplant.Thesehazardsincludebiological,chemical,psychologicalandergonomichazardtypes.Forthepurposeofthecasestudy,onlycuttingandseveringhazardsareoutlined.
Whenidentifyinghazardsassociatedwithplantandmachinery,itisbeneficialtolistthesituationsortaskswherethehazardmayoccur,anyassociatedactivitywiththesesituationsandtherelateddangerzones.
Appendix�containsalistofhazardsandsomedescriptionsofthesehazardsastheyrelatetomachineryandplant.Thislistshouldbeconsultedwhenundertakingariskassessmentonmachineryandplantandwillassisttoidentifyhazards,associatedactivitiesandsituationsanddangerzones.
Thecasestudybelowliststhehazardoussituations,associatedactivitiesandrelateddangerzonesrelevanttocuttingandseveringhazardspresentwhenusingamachiningcentre.
1. Identify hazards
Description of hazard Example of related hazardous situation
Associated activity Related danger zone
Cuttingandsevering Spindleortoolrunningorcutting
Spindlerunning Atspindleortool
2. Assess risks
Therearethreepartstothisstep:
(a) Estimatethelikelihoodofanincidentoraccidentoccurringattheworkplace.
Likelihood: How likely that it could happen?
Very likely couldhappenfrequently
Likely couldhappenoccasionally
Unlikely couldhappenbutrare
Very unlikely couldhappen,probablyneverwill
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland �5
Inthisexample,thepossibility(likelihood)ofinjuryfromapersoncomingincontactwitharunningorcuttingspindleortoolisassessedaslikely,i.e.itcouldhappenoccasionally.
(b) Estimatetheconsequencesofanincidentoraccidentoccurringattheworkplace.
Consequences: How severely could it hurt someone?
Extreme death,permanentdisablement
Major seriousbodilyinjury
Moderate casualtytreatment
Minor firstaidonly,nolostworktime
Theconsequenceoftherunningorcuttingspindleortoolcomingincontactwithapersonisassessedasextreme,i.e.deathorpermanentdisablement(suchasanamputation).
(c) Combinetheseestimatesoflikelihoodandconsequencestodetermineariskratingforeachrisk.ThiscanbeeasilyreadfromtheRiskAssessmentPriorityChartbelow.Thischartrankstherisksintermsoftheirpriorities.
Risk Assessment Priority Chart
Likelihood: ProbabilityHowlikelythatitcouldHappen?
Consequences:Howseverelycouldithurtsomeone?
EXTREMEdeath, permanent disablement
MAJORserious bodily injury
MODERATEcasualty treatment
MINORfirst aid only, no lost time
Very likelyCouldhappenfrequently
� 2 3 4
LikelyCouldhappenoccasionally
2 3 4 5
PossibleCouldhappenbutrarely
3 4 5 6
UnlikelyCouldhappen,probablyneverwill
4 5 6 7
Thefollowingscoresindicatehowimportantitistodosomethingabouteachrisk:
Score Action
�,2or3 Dosomethingabouttheserisksimmediately
4or5 Dosomethingabouttheserisksassoonaspossible
6or7 Theserisksmaynotneedimmediateattention
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland�6
Inthisexample,ariskratingof2iscalculated.Thisscoremeansthatsomethingmustbedoneaboutthisriskimmediately.Theassessmentcannowberepeatedforallotheridentifiedhazardsandsituations.
3. Determine controls
Associated activity
Related danger zone
Risk assessment Control
Score Action
Spindlerunning
Atspindleortool
2 Dosomethingabouttheserisksimmediately
Eliminationnotpossible.Substitutionnotpossibleatthispointintimeandwillbeconsideredasalong-termsolutionattheendofthemachiningcentre’slife.
Machiningcentreswillbesafeguardedwhereverpossiblebyfixedand/orinterlockingmoveableguards.Iffloor-mounted,theguardsshallbesecurelyfixed,ofadequateheightandfixedatasufficientdistancefromthedangerzones.Protectivedevicesmaybeusedwherefixedandinterlockingguardsarenotpossible(seeAS4024).
Meansshallbeprovidedforthemovementofmachineaxesforemergencypurposes(e.g.releaseoftrappedpeople).Thesemeansareforexample:
a) withpoweroff:-reliefvalvestodepressurisesystemsunderpressure
-manualreleaseofpower-actuatedbrakesprovidedthatweight-balancingexists
b) withpoweron:-manualcontrolfacilitiesofpower-pilotedvalves/drives
-controlfacilitiestostartcountermotions.
Controlswouldnowneedtobechosenforallotherhazardsassociatedwiththemachiningcentre.Thesewouldbeconsideredinorderofthehazards,withthehighestrisksfirst.
Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland �7
4. Implement controls
Associated activity Related danger zone Implementation
Spindlerunning Atspindleortool Priortointerlockingmoveablesafeguardsbeingfitted,thefollowingactivitieswillbeperformed.Theseactivitiesrelatetotheuseofthemachiningcentreafterbeingfittedwiththesafeguards:
(a) workprocedureswillbedeveloped,withinputfromworkers,formachinecentreuse,cleaning,maintenanceandemergencies
(b) training,instructionandinformationwillbeprovidedtoworkersregardingoperating,cleaning,maintenanceandemergencies
(c) supervisionwillbeprovidedtoensurecorrectuseandthatproceduresarefollowed.
5. Monitor and review controls
Associated activity Related danger zone Monitoring and reviewing
Spindlerunning Atspindleortool Supervisortocontinuallymonitorcompliancewithdevelopedprocedures.
Retraining(includinginstructionandinformationprovision)tobeprovidedwhenthereisachangetoworkpracticesormachineuseandatleastevery6months.
Operation,cleaning,maintenance,emergencyandotherprocedureswillbereviewedwhenthereisachangetoworkpracticesormachineuseandatleastevery6months.
Safeguardtobemaintainedregularly(atleasteverymonth).
Safeguardtobereviewedascontrolwhenthereisachangetoworkpracticesormachineuseandatleasteverysixmonths.
Whenthetimecomestoreplacethemachine,eliminationandsubstitution(saferalternatives)willbeconsidered.
Monitoringandreviewprocedureswouldnowbedevelopedforallhazardsassociatedwiththemachiningcentre.
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Section 3 - Guard design3.1 Types of guards
TechnicalassistancemaybefoundinrelevantAustralianStandards.ThestandardswithparticularrelevancetosafeguardingcommonmachineryandplantarelistedinAppendix5,togetherwithabriefdescriptionoftheircontents.Thesestandardsshouldbeconsultedforadditionalinformation.
Thereareanumberofdifferenttypesofguardsavailable,allsuitedtoparticularpurposes.Dependingonthesituation,acombinationoftwoormoreofthefollowingmeasuresmaybeusedtoensureworkers’safety.Therangeofguardsincludesbutisnotlimitedtofixed,interlocking,hinged,movablebarrier,automatic,distanceandtripguards.Examplesofthesetypesofguardsaredetailedbelow.
3.1.1 Fixed guardsFixedguardsarestationaryguardsandpreventcontactbetweenmovingmachinerypartsandanypartofthebody.Theyofferprotectiononlywhenproperlyfixedinposition.Fixedguardsshouldbeeasytoremoveandreplace,butonlybeabletobeopenedorremovedwiththeaidofatoolandwhenthemachineisnotinoperation.
Illustration 11-Anexampleofafixedguard.
3.1.2 Interlocking guardsInterlockingguardspreventmachineryandplantfrombeingoperated,unlesstheguardisinplace.Interlockingguardssuchasenclosureguardsareknownasmovableguardsandhavethemovingpartinterconnectedwiththecontrolsystem.Interconnectionsareusuallyelectrical,mechanical,hydraulicorpneumatic.
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Examplesofmovableinterlockingguards,whichareinterlockedwiththepowersourceofthehazardtoensurethatwhenevertheguarddoorisnotclosedthehazardpowerisswitchedoff,areshownbelow:
Illustration 12-Anexampleofahingedoorguard(interlockingmovableguard)
Illustration 13-Anexampleofaslidingdoorguard(interlockingmovableguard)
3.1.3 Automatic guardsAutomaticguardsareself-adjustingandautomaticallymoveintopositionasthemachineorcyclestarts.Theyarealsoknownaspush-awayguards.Theseareonlysuitableonslowmachines.
Illustration 14-Anexampleofapush-awayguard(automaticguard)
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3.1.4 Distance guardsDistanceguardspreventaccesstodangerousareasthroughabarrierorfence.Anyaccesspointsthroughtheguard(e.g.gatesanddoors)mustbesecuredwithalockorinterlockingsystem.
Illustration 15-Anexampleofadistanceguardfittedtothepressbrake
3.1.5 Trip guardsTripguardsarepresence-sensingandstopthemachinewhenapersongetsintoapositionwheretheyareliabletobeinjured.Photoelectriccurtains,laserscannersandpressurematsareexamplesofthistypeofguard.
Illustration 16-Anexampleofaphotoelectriclightcurtainusedasatripguard.Whenanyofthebeamsareblockedbyintrusiontowardsthehazardarea,thelightcurtaincontrolcircuitswitchesoffthehazardpower.
AS4024.1Safeguarding of machinery – General principlesprovidesmoreinformationinrelationtotypesofguardsandcategoriesofreliability.Thisstandardshouldbeconsultedforadditionalinformation.
AS61508.1 Functional safety of electrical/electronic/programmable electronic safety-related systems – General requirementsprovidesmoreinformationinrelationtosafetyintegritylevels.Thisstandardshouldbeconsultedforadditionalinformation.
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3.2 Basic rules for guard designTheprimaryfunctionofaguardistoprovideaphysicalbarrierbetweenaworkerandthedangerouspartsofmachineryorplant.Whenselectingcontrolmeasures,carefulattentiontodesignandlayoutattheoutsetcanavoidlaterproblems.Basicrulesforguarddesigninclude:
• ensurethematerialsusedareofsuitablestrengthandgoodquality• havinganysortofguardmaynotbeenough.Poorlydesignedorinappropriateguardinghas
contributedtoinjuriesfrommachineryorplant.Ideallyaguardshouldbecustom-designedforthemachineandtheworkprocess
• interlockdevicesmayneedtobeusedinconjunctionwithothertypesofguardingtoensuresafety
• avoidsecondbestwhendesigningaguard.Ifaguardisusedfromanothermachine,itmustbecheckedcarefullytoensurethatitisnotdefective,thatitfitsthetargetmachine,isofsuitablestrengthandqualityforthenewapplicationandthatitachievestheaimofcontrollingtheriskpresentedbythetargetmachine.
Indeterminingthemostappropriatecontrolmeasureforthehazard,riskandmachine,otherissuesorrisksshouldalsobetakenintoconsideration.Guardingcanplayausefulroleinbothdustandnoisereduction.Inmanycases,issuesofwear,heatandventilationaffectoperatingefficiencyandmayalsohaveconsequencesforworkerhealthandsafety.
3.3 Servicing considerationsGuardsshouldbedesignedforeasyremovalandreplacement.Thesetypesofguardmaketaskssuchasregularcleaning,maintenanceandmachineadjustmentorbeltchangeseasier,particularlyifthisworkneedstobedonefrequently.Safeproceduresforremovalofguardsforrepair,ortoclearjamsorbreakdownsmustbeconsidered.Inallcases,guardsshouldbedesignedsotheycanonlyopenorberemovedwiththeaidofatoolandwhenthemachineisnotinoperation.
Servicingissuesinclude:
• documentedsafeworkprocedures,includingreferencetomanufacturer’srecommendations• proximitytohotorsharpparts• cooldownorwarmupperiods• lock-outprovisionsorpermissionforguardremoval• sufficientroomtoperformtaskswithoutriskofinjuryorstrain• anyadditionalhazardsarisingfrommaintenanceprocedures(e.g.testingwhilemachineis
unguarded[‘dryrun’],workingatheights,useofsolvents)• maintenanceofservicingrecords.
3.4 Ergonomic considerationsThefollowingtablesandillustrationswillprovidehelptoassesswhereandwhatsortofguardingisneededtokeepadangerpointonamachinesafelyoutofreach,takingintoaccountthephysicalcharacteristicsofworkers.
3.4.1 Reach measurementsMachinesaredesignedforanaverageworker—typicallya�72cm(5ft8in)male.Ifworkersaresignificantlytallerorshorterthan�72cm,thenemployersshouldconsiderwhetherthestandardmachineguardingmethodsandworkprocessesarestillsafe.
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Thedesignandpositioningofguardsshouldprovideatleastthefollowingclearance:
Reach Minimum distance assumedArmreach Greaterthanorequalto850mmfromunderarm
tofingertip
Elbowreach Greaterthanorequalto550mmfromtheinsideelbowtofingertip
Wristreach Greaterthanorequalto230mmfromwristtotipofmiddlefinger
Fingerreach Greaterthanorequalto�30mmVerticalreach 2500mmmaximumwhenstandingontoes
3.4.2 Guard placement
Thesizeofmeshorotheropeningsintheguardandthedistanceoftheguardfromthedangerpointcanbeselectedbasedonthefollowingguide:
Meshsizeopeningsuptoandincluding9mm Distanceofguardfromdangerpointvirtuallythesame
Meshsizeover9mmbutlessthan40mm Guardatleast200mmfromdangerpoint
Alltypesofguards Distancebetweenbottomopeningandfloornottoexceed250mm
Simple gap/distance formula
Thefollowingformulaprovidesaneasymethodfordeterminingtherequiredgapormeshopenings,andthedistancetheguardshouldbefromthedangerpoint:
Gap = Distance + 6mm �0
Noadmittance Reachrestrictedtorootoffinger
Reachrestrictedtorootofthumb
Reachrestrictedtohandthickness
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Reaching down and over
Inthefollowingdiagramandtable:
A =distanceofdangerpointfromthefloororworkingsurfaceB =heightofthebarrierC =horizontaldistancetobemaintainedbetweenedgeofbarrieranddangerpoint
Note: Barriers must not be able to be stepped over.
A – distanceofdangerpointfromfloor(mm)
B - heightofthebarrier(mm)
2400 2200 2000 �800 �600 �400 �200 �000
C - horizontaldistancetobemaintainedbetweenbarrieranddangerpoint(mm)
2400 - �00 �00 �00 �00 �00 �00 �00
2200 - 250 350 400 500 500 600 600
2000 - - 350 500 600 700 900 ��00
�800 - - - 600 900 900 �000 ��00
�600 - - - 500 900 900 �000 �300
�400 - - - �00 800 900 �000 �300
�200 - - - - 500 900 �000 �400
�000 - - - - 300 900 �000 �400
800 - - - - - 600 900 �300
600 - - - - - - 500 �200
400 - - - - - - 300 �200
200 - - - - - 200 ��00
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Section 4 - Guards for different machine types 4.1 Exposed rotating cutting processesExposedrotatingcuttingmachineryincludescut-offsaws,millingmachines,frictioncuttingandboringequipment.Thehazardarisesfromtheexposedblades,andrisksincludecuttingfleshorlimbs,orentanglement.
Themostappropriatetypesofguardsarefixedormovingguards.
Illustration 17-Self-adjustingguardforadropsaw
Aparticularpointtonoteistheself-actuatingvisorfittedtothefixedguard.Ifthisvisorisnotaffixed,thecuttersteethareexposedwhenthemachineisatthetopofitsstroke.Asthecutterisloweredthevisorautomaticallyrises.
4.2 Pulleys and drivesPulleysanddrivesareusedinarangeofmachinery.Themainhazardisnip-points,andallneedtobeguardedsoastobeoutofreachforoperatorstopreventtheriskofentanglement.
Fixedguardsarepreferredforpulleysanddrives.Insomecases,ahingedsectionmaybeappropriatetoenableaccessduringmachinesetting.Suchcontrolmeasuresmustbedesignedandinstalledsothatatoolisrequiredtoremoveandreplaceaguard.
Illustration 18-Fixedguardforapulleyanddriveconstructedofwiremeshandanglesectionpreventingaccesstotransmissionmachinery
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4.3 Rotating shafts and rollersFixedguardsarepreferredforrotatingshaftsandrollers.Guardsmustprovideprotectionagainstlooseclothingandlonghairgettingentwinedwithrotatingshafts.Appropriateworkprocessesmayincludetherequirementthatoperatorsnotwearlooseclothing,andtielonghairbackorwearheadcovering.Examplesofrotatingshaftsincludecouplings,spindles,fan-shaftsandironingrollers.
Illustration 19-Fixedguardonrotatingshaft/coupling
4.4 Safety devicesSafetydevicesaredesignedtosenseapersonorpartofthebodyandinitiatethestoppingofadangerousmotionperformedbythemachinebeforeaccesscanbegainedtoadangerousareasurroundingthemachine.Safetydevicesalsoensurethatapersonorpartofthebodycannotgainaccesstoadangerousareaofthemachineasaresultofthedesign,placementorjunctionofmachinecontrols.Someexamplesofhowsafetydevicescanbeusedareillustratedbelow.
Illustration 20 -Anexampleofaphotoelectriclightcurtainusedasatripguard.Whenanyofthebeamsareblockedbyintrusiontowardsthehazardarea,thelightcurtaincontrolcircuitswitchesoffthehazardpower.
Illustration 21–Two-handedcontrols
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Illustration 22-Pressuresensitivemat
4.5 Combination of guarding and safety devicesAcombinationofguardingandsafetydevicescanbeusedtoensureallhazardsandrisksassociatedwiththemachinehavebeenaddressed.Illustratedbelowisanexamplewhereacombinationofguardingandsafetydeviceshasbeenused.
Illustration 23-Papercuttingguillotinefeaturingacombinationofguardingandsafetydevicessuchasphotoelectricguarding,fixedsideguardandtwo-handedpushbuttoncontrols.
4.6 Safe work rules and practices4.6.1 IsolationWiththeexceptionofthosecircuitsrequiredforsafetysystems,allmachineryshouldbefittedwithameansofisolationfromallenergysources.Suchisolatorsshouldbeclearlyidentifiedandbecapableofbeinglockedifreconnectioncouldplacepeopleatrisk.
Anappropriateisolationmethodisalock-out/tag-outsystem,inwhichoneormorepadlocksarefittedtotheisolationswitch,withkeysbeingheldbytheoperatorsormaintenancepersonnel.Theirnameandreasonforthelock-outarewrittenonthetagsattachedtothepadlock.Whenthetaskiscompleted,thelocksandtagsareremovedandpowercanberestored.
4.6.2 Emergency stop devicesEmergencystopdevicesmustbelocatedwhereanoperatorcaneasilyreachthem.Poorlylocateddevicesmayencouragedangerouspractices,suchasreachingacrossmovingparts,afailuretoshutdownmachineryorplantwhenaproblemoccurs,orsituationswherethemachineorplantcanbestartedbyoneworkerwhileanotherisinadangerouslocation(e.g.cleaningabin).
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Thenumberofemergencystopdevicesrequiredneedstobeconsidered.Ifthemachineorplantislarge,severaldevicesmaybenecessary.Whentherearemultipledevices,safeoperatingpracticesmustbeadoptedsothatmachineryorplantisnotrestartedwhenitisundergoingmaintenanceorothertemporaryoperations.Alock-out/tag-outsystem,asoutlinedabove,isthereforeanessentialpartofisolatinganenergysourcetopreventaccidentalplantstart-up.
4.6.3 Inspection, cleaning, repair, maintenance and emergency proceduresTosafeguardoperatorsandotherstaff,cleaning,repair,maintenanceandemergencyproceduresmustbeinplaceandunderstoodbyworkers.Aregularinspectionregimeshouldbeinplacetoidentifyanyproblemswithplantandmachineryandsafeguards.Anyadditionalhazardsassociatedwiththeseactivitiesmustbeidentifiedandassessedaspartoftheriskmanagementprocess.Specialprecautionsneedtobetakenwhereworkersundertakingthesetasksareobscured,orwheretherearemultipleoperatingswitches.Applyisolationprocedureswhenevermaintenanceorrepairrequirespeopletoenterthedangerareaaroundmachinery.
4.6.4 Opening and removing guardsGuardsmustonlybeabletobeopenedorremovedwiththeaidofatoolandwhenthemachineisnotinoperation.
4.6.5 WeightLargemachineryorplantmayrequireextensiveguarding,andtheseguardsmayneedtoberemovedformaintenanceaccess.Whilesomesectionsmayremainfixed,itispreferablethattheguardbedividedintoeasilyremovablesections.Sectionsshouldbedesignedtoberemovedandhandledeasilybyoneperson.Appropriateplacementofhandlesonmovablesectionswillfacilitateeaseofremoval,liftingandhandlingandthusreducetheriskofmanualhandlinginjuries.
4.6.6 Interactions Guardsthatmoveoutofthewayforeachoperation(automaticguards)needspecialconsideration.Watchforpotentialrisksintheinteractionsbetweenguardandmachine,betweenguardandpersonandbetweenguardandwork-piece.
4.6.7 Colour codingItisgoodpracticeforallsafetyguardstobepaintedthesamecolour.Forexample,usehighvisibilityyellow(provideditisdifferenttothegeneralmachinerycolour)sothatitcanbeclearlyseenwhenaguardhasbeenremovedorwhenitisnotinitsproperplace.Itisalsogoodpracticetopaintthesurfacesbehindtheguardadifferentcolour(e.g.blueorred),sothatwhentheguardhasbeenremoved,theexposedcolourisclearlyvisible.Itistheneasytoidentifythattheguardhasbeenremovedandworkersarealertedtopossibledanger.
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Section 5 – Safeguarding of power presses, conveyors and roboticsDuetotheirinherentrisks,somemachineryandplantrequiresspecificguarding.Specificguardsandpracticesareprovidedhereforconveyorsandforroboticsandforthetwocategoriesofpowerpresses—powerstampingpressesandbrakepresses.Thesemachinespresentanumberofhazardsandrisksrequiringcontrol.
5.1 Power stamping presses Powerstampingpressesaremachinesusedforstampingvariousmaterialsbytheclosingactionoftwoparts—onemoving(punch)andonestationary(die).Theproductisformedwhenthepunchanddiearebroughttogetherbyforcegeneratedbyamotorandflywheel.Therearetwomaindrivesystems—keyclutchandhydraulic.Operationmybeeitherbyautomaticfeedorbymanualoperation,whereeachindividualpieceofmaterialtobeformedisplacedintothedieareabytheoperator.Itisinthismodeofoperationthatmostpowerpressinjuriesoccur.
5.1.1 Hazards and risksThemainhazardofapowerstampingpressiswherethepunchanddiecometogethertoformtheproduct.Theimpactwouldhaveacrushing,cuttingorshearingmotionwhichcreatesariskofhavingapartofthebodycrushedorcut.Drivebeltshavein-runningnippointswhichpresentariskofentanglementandabrasion.
5.1.2 Control measuresDependingonthetypeofjobtobecarriedout,therearevariouswaysofguardingthesepresses.Optionsinclude:
• Fixed guarding:Afixedguardhasnomovingpartsandoffersprotectiononlywhiletheguardisinitscorrectposition.Operatoraccesstothehazardousareaisprevented,howeverwiththeaidofatool,slidescanbeadjustedtoallowworktobefedthroughtheguardintothestampingarea.
• Interlocked guarding: Aninterlockingguardisaguardwhichhasamovablepart,whichisinterconnectedwiththe
powerorcontrolsystemofthemachinesothatuntiltheguardisclosed,theinterlockpreventsthemachinefromoperating.Withthekey-clutchtypeofpressfittedwithinterlockedguarding,itisalsonecessarytofitananti-repeatdevicetopreventapowerstrokeintheeventofaclutchfailure.
• Presence-sensing devices (photoelectronics):Presence-sensingdevices(photoelectronics)detectthepresenceofaperson,orpartofaperson,inadefinedarea,andpreventthedangerouspartsofmachineryfrommovingwhileanyoneisinthatarea.Presence-sensingdevicesareonlysuitableforhydraulicmachines,andinstallationofthesedevicesshouldcomplywithAS4024.1 Safeguarding of machinery – General principles.
• Two-handed controls:Two-handedcontrolsareonlysuitableforhydraulicmachines.Thissystemrequiresbothhandstooperatethemachinecontrolsandshouldbedesignedinaccordancewiththefollowing:• controlsshouldbeseparatedandprotectedtopreventspanningwithonehandonly• itshouldnotbepossibletosetthedangerouspartsinmotionunlessthecontrolsareoperated
withinhalfasecondofeachother• ifoneorbothcontrolsarereleased,movementofthedangerouspartsshouldbestopped
immediately
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• thecontrolsshouldbepositionedatsuchadistancefromthedangerpointthat,onreleasingthecontrols,itisnotpossiblefortheoperatortoreachthedangerpointbeforethemotionofthedangerouspartshasbeenstopped
• rearandsideguardingofthemachineisrequired.
• Administrative controls:Regularmaintenanceof‘key-clutch’pressesisextremelyimportant.Inspectionandmaintenancerecordsshouldbekepttodemonstratethatmaintenancehasbeencarriedout.Regularsystemsauditsandsafetyinspectionsshouldbecarriedouttoensurethatstandardpracticematchesstatedprocedures.Safetyinspectionsshouldincludetheconditionandoperationofthefollowing:• flywheelbearingandshaft• extractorcamandkey• anti-repeatdevice• brakes• guards• safetydevices• controls.
Maintenance problem areas
�.Clutchmechanism 6.Guardcontrol2.Brake 7.Linkageandattachments3.Fywheelbearing 8.Toolsetter'sdisconnection4.Pitmanscrew 9.Distortionanddeteriorationofguardgates5.Clutchinterlock �0.Guardoverfootpedal
Illustration 24-Thisisapowerstampingpress.Performingmaintenanceonpowerpressescanbringmaintenancepeopleintocontactwithhazardousareasonthepowerpress.Theaboveillustrationidentifiescommonproblemareasonapowerpress.
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Flywheel seizure:Theflywheeljournalbearingsmustbekeptwell-lubricatedandclean.Themajorityofpresseshaveballorroller-bearings,butsomeimportedmachinesdohaverollingkeys.Thedesignofrollingkeyclutchesissuchthatplainbronzebearingsareanecessity.Anymetallicfragmententeringthebearing,orasimplelackoflubrication,couldcausethebearingtoseizeonthejournalofthecrankshaftandanuninitiatedstroketooccur.
5.2 Press brakes (mechanical and hydraulic)Apressbrakeisamachinegenerallylimitedtolinearbendingandformingofmaterial(e.g.sheetmetalandheavygaugematerial).
5.2.1 Hazards and risksThemainhazardofapressbrakeiswherethepunchanddiecometogethertoformtheproduct.Theimpactwouldhaveacrushing,cuttingorshearingmotionwhichcreatesariskofhavingapartofthebodycrushedorcut.Drivebeltshavein-runningnippointswhichpresentariskofentanglementandabrasion.Hydraulichosesmayposeariskiftheyleakorburst.Risksmayincludespillscreatingasliphazardandhydraulicfluidscomingintocontactwithworkers.
5.2.2 Control measuresDependingonthetypeofjobtobecarriedout,therearevariouswaysofguardingthesepresses.Wherepressbrakesarebeingusedforspecificrepetitivejobs,fixedguardsmaybeappropriate.However,forgeneraluse,whereworkershavetoholdorstabilisethematerial,orneedfrequentaccesstoclosingdies,thesemachineswouldrequirepresence-sensingdevicestoensuresafeoperation.Presence-sensingdevicesmaybelightcurtainsorlightbeams.Automaticstopsmustalsobeguardedandback-gaugingequipmentisrecommended.
Presence-sensing systems—light curtains
Lightcurtainsconsistofseveralpairsoflightboxunitsandacontrolbox.Eachlightboxpairhasatransmitterandreceiver.Thetransmittergeneratesacurtainofhighintensity,micro-secondinfra-redlightpulses,acrossthemachineoperator’sworkarea.ThiscurtainoflightistransmittedanappropriatedistancefromthehazardousareaasdeterminedinaccordancewithAS4024.1 Safeguarding of machinery – General principles,orasdeterminedbyariskassessment.Anyintrusionintothislightcurtainproducesasignalforthecontrolboxtostopthemachine.Inordertoassisttheoperator,theselightcurtainsystemshaveavarietyofoperatingmodeswhichmaybesetaccordingtothetypeofworkbeingdone.Forexample:
• continuousstrokingmode—whenthecontrolpedalisdepressed,themachinewillmovefromthetopofthestrokeandcontinuetostrokewhilethepedalisdepressed.Ifthelightcurtainispenetratedwhilethemachineisdown-stroking,themachinewillstop
• top-to-topmode—themachineoperatesasinthecontinuousmode,exceptthat,regardlessofwhethertheoperatorreleasesthefootpedal,themachinewillstopatthetopafteronecycle
• bottomstopmode—themachinestartsfromthetopofthestrokewhenthepedalisdepressed,andstopsleavingadaylightgapbetweenthetopandbottombeam,inaccordancewithAS4024.�Safeguardingofmachinery–Generalprinciplesorasdeterminedbyariskassessment.Atthispointthelightcurtainismutedorbypassed.Depressingthepedalagainmovesthemachinetothebottomofthestrokeandreturnsittothetopwhereitstopsandatthispointthelightcurtainisreactivated
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• bottomstop-to-bottomstopmode—similartothebottomstopmodeexceptthemachinedoesnotstopatthetopofthestroke.Itstopsatthe6mmgapmuteposition,orwhenthelightcurtainisobstructedonthedownstroke
• pulsingmode—thelightcurtainismutedorbypassedandthemachinecanbemoveddownin�0mmincrementswitheachdepressionofthepedal.Thismodeallowstheoperatortostandinsidethecurtainforclosework
• linkmode—isusedformechanicalpressesandissimilartothebottom-stopmode,excepttheinitialdownstrokeiscontrolledbyanelectricfoot-switchandatthe6mmmutepoint,thepedalcontrollingthemechanicalfrictionclutchisoperatedtofinalisethestrokeofthemachine.
Presence-sensing systems—light beams
Thistypeofguardingsystemconsistsofthreeinfra-redlightbeamsmountedonthepress-brakeblade.Thefrontbeamprotectstheoperator,whileallowingworktobeperformedclosetotheblade.Thecentrebeamsetsthemutebypasspoint.Therearbeamprotectspeopleattherearofthemachine,eliminatingtheneedformechanicalguarding.
Onoccasionsitmaynotbepossibletoperformworkwiththeguardingsysteminplace.Specificguidanceforthesystemstobeimplementedwhenguardingisremovedorswitchedoff(muted),isdetailedinClause6.4.3ofAS1219 – 1994 Power presses – Safety requirements.However,iftheworktobeperformedrequiresguardingtoberemovedonaregularbasis,themachinemaynotbesuitablefortheapplication.Measuresshouldthereforebetakentouseanothermachineortomodifytheexistingmachinesothattheguarddoesnothavetoberemoved.
Intheeventoftheneedtoinvokeclause6.4.3,andregardlessofwhetheroption(a),(b)or(c)inthatclauseisselected,thereisstillarequirementtoinstallsuitableguardingtoprotectoperatorsfromhazardsattherearandsidesofthemachine.Intheeventthatoption(c)ofclause6.4.3isselected,allsevenrequirementslistedin(c)mustbemet.
Additionally,asafesystemofworkshouldbedocumentedandtheoperationsupervisedbyacompetentperson.
AS1219 - 1994 Power presses – Safety requirementsprovidesmoreinformationinrelationtoguardingdevices,theirdesign,manufactureandthesafeguardingofpowerstampingpressesandbrakepresses.Thisstandardshouldbeconsultedforadditionalinformation.
5.3 Conveyors (bulk handling)Conveyorsareameansoftransportingmaterialsfromonepointtoanother.Differenttypesincludebeltconveyors,screwconveyorsandbucketconveyors.
5.3.1 Hazards and risksThemainhazardsofaconveyorarethenumerousin-runningnippointswhichpresentariskofentanglement,crushingandabrasion.Thedrivesystemitselfmayalsoposerisksofentanglementorabrasion.
5.3.2 Control measuresFixedguardswhichenclosein-runningnippointsandthedrivemechanismareoftenthemosteffectivewaysofsafeguardingconveyors.Thefollowingexamplesshowthenumerousdangerpointsonastandardconveyorandwaystoguardtheheadandtailsectionsoftheconveyor.Allguardsshouldbedesignedforeasyremovalandshouldrequiretheuseofatoolforremovalandreplacement.
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Illustration 25-Dangerpointsonastandardconveyor
Illustration 26-Typicalguardforheadandtailsectionofaconveyor
Itisimportanttonotethatphysicalguardingisnottheonlyguardingoptionforconveyorsystems.Othersafeguardsinclude:
• Electrical isolation (lock-out/tag-out)Althoughsafeguardsareprovidedwhichpreventaccessduringmostphasesofmachineryorplantlife,theymaynotbeeffectiveatalltimesbecauseoftheneedtogainaccesstohazardousareasduringmaintenance,set-up,etc.Isolationproceduresshouldbedevelopedbytheemployerwhichareappropriatefortheparticularmachine.Theseprocedurescouldincludevarioustypesoflocks,keysanddangertags.Atypicallock-out/tag-outsystemforconveyordriveswouldbetoapplyalocktotheisolationswitch,aswellasadangertagwiththemaintenanceperson’snameonit.
• Start and stop controlsConveyorsshouldbeprovidedwithappropriatedrivepowerisolation,whetherelectrical,hydraulic,pneumaticormechanical.Isolationshouldbesecuredbymeansofalock-out/tag-outsystem.Ateachconveyorstartlocation,aclearlylabelled’stop’controlshouldbeprovided.Wherethestartcontrolisinapositionfromwhichthewholeoftheconveyoroperationcannotbeviewed,avisibleoraudiblesignalshouldbeprovidedtowarnpeopleinthevicinity.
• Emergency stop controlsAlanyardtypepull-wireemergencystopisthemostsuitableemergencystopforexposedbelttypeconveyorswhereworkersarerequiredtoaccessthebeltareawhentheconveyorisinuse(e.g.placingandremovingparcelsatatransportdepot).Thelanyardtypeallowsaccesstotheemergencystoppingfacilityfromallofthepointswhereapersonmaybeworkingduringtheconveyor’suse.Emergencystopcontrolsmustbemanuallyresetbeforetheconveyorcanberestartedfromitsnormalstartcontrol.
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• Access provisionsMachinerydesignshouldallowallroutineadjustment,lubricationandmaintenancetobecarriedoutwithoutremovingguardsorextensivedismantlingofcomponents.Lubricationandroutinemaintenancefacilitiesshouldbeincorporatedoutsidethedangerareawhereverpractical.However,whenpeoplerequireaccesstothedangerarea,forexampleformachinesetting,safeisolationproceduresshouldbeused.
• LightingProvidelocallightingonthemachineforlightingtheworkareawhenthemachineorguardsrendernormallightinginadequateforsafeoperation.Locallightingshouldalsobeprovidedinregularmaintenanceareasthatarepoorlylit,forexampleinsidecertainelectricalcompartmentswhereelectricalisolationisnecessaryforaccess.
AS1755 – 2000 Conveyors - Safety requirementsprovidesmoreinformationinrelationtominimumsafetyrequirementsforthedesign,installationandguardingofconveyorsandconveyorsystems.Thisstandardshouldbeconsultedforadditionalinformation.
AS1680.1 – 1990 Interior lighting – General principles and recommendationsprovidesmoreinformationinrelationtothegeneralprinciplesandrecommendationsforlighting.Thisstandardshouldbeconsultedforadditionalinformation.
5.4 Robotics Acommonmisconceptionisthatroboticoperationsare‘safe’becausethereislittleornoworkerinteraction,howevermosthealthandsafetyissueswithrespecttoroboticsareinrelationtoinstallation,repairandmaintenance.Whileoperationmaybesafe,ariskassessmentmustbeundertakentoensureworkers’safetyduringallphasesofthemachinerylifeanduse.Robotshaveoftenbeenusedtoremovethemoretraditionalhazardsassociatedwithmachineryandalsotoperformsomehigh-riskoperations,forexampleinthebiotechnologyfield.
Theriskmanagementprocessshouldbefollowed,withreferencetomanufacturer’sinstructions,duringinstallation(commissioning),testingandstart-up,repairandmaintenance.
5.4.1 Hazards and risksRobotshaveinherentdangersincludingunpredictableactionpatterns,highspeedoperations,abilitytomoveinfreespace,andabilitytobereprogrammedorreconfiguredtochangetheiruseandapplication.Someofthehazardsassociatedwithindustrialrobotoperationinclude:
• ImpactRobotsmaymoveinadirectionnotanticipatedorplanned,athighspeedinlinearorrotarydirections.Therobotmayalsoejectwork-pieces,off-cutsormoltenmetal.Workersareatriskfrombeinghitbytherobotorpartsofthework.
• Trapping pointsTrappingpointsmaybecreatedbymovementsoftherobotorassociatedequipmentsuchasworkcarriages,palletsortransfermechanisms.Ontherobotitself,trappingpointsmaybeidentifiedonthearmoftherobot,betweenthearmandthecolumn,andbetweenthearmandfixedobjects.Workersmaybecrushedorbecomeentangledbytherobotortheprocess.
• Control errorsControlerrorsresultfromintrinsicfaultswithinthecontrolsystemoftherobot(e.g.software,electricalinterference,programcorruptionandsub-controlsassociatedwiththeelectrics,hydraulicsandpneumatics).
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• Human errorHumanerrorcouldoccurduringprogramming,teaching,andmaintenanceandrepair,orinworkhandlingclosetotherobotoratload/unloadstations.
• Failure or malfunctionFailureormalfunctionofelectrics,hydraulicsandpneumatics.
• Biological or chemical hazardsHazardsmayoccurwhererobotsarebeingusedtoreducetherisksfromhazardousorinfectiousprocesses.Workersmayriskinhalingorabsorbinghazardoussubstances.Inthiscase,particularattentionmustbepaidtotheprocessitselfandtoanybreakdownoremergencyproceduresthatmayresultfromspillage,contaminationorbreachofthesystem.
• Environmental hazardsHazardsincludedustvapour,fumes,lasers,radiations,andflammableandexplosiveatmospheres.Workersmayriskinhalingorabsorbinghazardoussubstances,burnsandotherinjuries.
5.4.2 Control measuresHazardsassociatedwithmovingparts,otherthanatpointofoperation,shouldbeeliminatedbydesign,orelseprotectionmustbeprovidedagainstthehazards.Industrialroboticinstallationsmaybesafeguardedbyoneormoreguardingandpresencesensingdevices.Enclosureisafrequentcontrolmeasureforroboticsystems.
Thehighlytechnicalandprogrammablenatureofrobotsmeansthatadditionalsafeguardsshouldbeconsideredinadditiontotheguardingofdangerousmovingparts.Measuresshouldbetakentopreventunauthorisedaccesstocontrolsandtoprotecttherobotsystemfromunintendedoperation.
Attentionmustalsobepaidtocontrollinghazardsinadjacentareas—forexample,loadingorunloadingstationsandassociatedequipment.Inparticular,removalofassociatedequipmentsuchasconveyors,transfersystemsandtrolleys,mustnotallowaccesstorestrictedareas.Ifso,thesepointsmustbeguarded.
Control systems
Actuating(start)andcontrolsystemsforroboticsareusuallyoftheprogrammableelectronictype.Thesemustbeprotectedagainstunauthorisedaccess,forexamplebylocationinalockablecontrolcabinetorroom.Controlsshouldbeconstructedorlocatedtopreventunintentionaloperation.Thiscanbeachievedbyshrouding,guarding,gating,appropriatelypositionedorotherwisedesignedtopreventaccidentaloperation.
Master switches
Masterswitchesmustbeprovidedtoisolateallmotivepowerfromtherobotandmaybethesamedeviceasanemergencystopdevice.Thismasterswitchshouldbecapableofbeinglockedintheisolatingpositionandrequiremanualresetting.
Fixed or distance guards
Guardsmaybeusedwheretheguardwillnotinterferewiththemechanismoftherobot.Itmustbenecessarytousetoolstoremovetheguardsinordertogainaccesstotherestricteddangerarea.Guardsorfencesmustbelocatedtopreventpeoplefromreachingintoarestrictedarea.Anyopeningsprovidedforfeedingmaterialintotheprocessshouldbedesignedtopreventaccessbyanypartofaperson.
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Interlocked guards
Interlockedguardsinitiateanemergencystopwhenopened.Whilesuchaguardmustpreventinitiationofautomaticoperation,itmaymaintainpowerforotherfunctions.Returntoautomaticoperationwouldthereforerequireboththeclosingoftheinterlockedguardandtheactivatingofastartprocedure.
Presence-sensing devices
Presence-sensingdevicesmustbedesignedandpositionedtodetectentryintoarestrictedspaceordangerareaandtocausetheautomaticoperationoftherobottoceasewhenentryisdetected.Thefailureofthisdevicewouldalsocausetherobottoceaseoperation.
• Photoelectricsystemsconsistofacombinationofaphotoelectricdevice(e.g.alightcurtainorbeam),robotcontrolsystem,driveandbrakeunitsand,whereappropriate,anoverallperformancemonitor.Interruptionofthelightcurtainwillcausetheoperationoftherobottocease,thereforeitshouldnotbepossibletostandorplaceabodypartbetweenthelightcurtainandthehazardouspartoftheprocess.Photoelectricdevicescanbesettocontrolthesizeofanypenetration(e.g.ahandbutnotthearmoranarmbutnotthebody).
• Pressure-sensitivematsoperatebymeansofanumberofsuitablyspacedelectricalorfluidswitchesorvalvescontainedwithinamatcoveringtheapproachestoarestrictedspace.Pressureonthematwillcausetheautomaticoperationofthemachinetocease.Suchaguardmustbedesignedsothatitisnotpossibletocircumventoroverstepapressure-sensitivematintoarestrictedarea.
Training
Inadequatetrainingmayincreasetherisksatmoststagesofrobotoperation.Appropriatetrainingisconsideredessentialwhencontrollingtherisksassociatedwithindustrialrobotmachines.
Safe work systems
Safeworksystemsarearecommendedcontrolmeasuretominimisesomeoftherisksassociatedwithrobotics.Adocumentedsafeworksysteminvolvesrecordingproceduresforentry(includingwhoispermittedtoperformidentifiedtasks),access,maintenanceandrepair.
Inspectionandmaintenanceactivitiesmayprovideadifferentsetofhazardstoperformanceormonitoringofwork,andmustalsobeassessedintermsofhazardsandrisks.
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Illustration 27-Typicalmanufacturingsystemusingarobotasthematerialhandlingsystemwhereperimetermarking/barrier,fixedbarrierswithinterlockedgates,presence-sensingdevices,warningdevicesandadditionalsystememergencystopdevicesareused.
AS2939 – 1987 Industrial robot systems – Safe design and usageprovidesmoreinformationinrelationtotherequirementsofthedesign,construction,safeguardingandinstallationofindustrialrobots.Thisstandardshouldbeconsultedforadditionalinformation.
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Section 6 - Other machinery safety issues
Itshouldbenotedthatthefollowingsub-sectionsarenotanexhaustivelistof‘othermachinerysafetyissues’.AS4024.1 Safeguarding of machinery – General principles providesmoreinformationinrelationtoanumberofotherissuesnotmentionedinthissection.Thisstandardshouldbeconsultedforadditionalinformation.
6.1 Work organisation Managementhasakeyroleinestablishingandmaintainingsystemsandprocessesthatmonitorandevaluatepotentialhazards.Followingtheriskmanagementprocesswillassistemployersandpeopleconductingabusinessorundertakingtoensurethesafetyoftheirworkersandthoseconductingworkactivities.Commitmentisrequiredfromallworkers,fromseniormanagementrightdowntotheshopfloor.Productionratesanddeadlinesshouldbeplannedsothattheycanbeattainedwithoutcompromisingsafeworkpractices.
Formachineguardingtoworkeffectively,themovementofmaterialson-siteandthejobproceduresappropriatetothemachinerymustbethoroughlyunderstood.Safemachineryoperatingproceduresorinstructionsformachineryorplantshouldbedeveloped,andworkersappropriatelytrainedtoensuresafeworkpracticesaremaintained.
Newrisksshouldnotbeintroducedintotheworkplacebecauseoftheintroductionofnewtechnology,newmachineryorplant,ormodificationstoexistingmachineryofplant.Atthesetimesriskassessmentsmustbeperformed,ideallyinconsultationwithworkers.
6.1.1 LayoutMachineguardingwillbemoreeffectiveifitisusedinconjunctionwithproperattentiontolayout.Machineswhicharepoorlylocatedortooclosetogethermaynotbesafe,evenifguarded.Thereareanumberofbasicpointstoconsiderinrelationtolayout:
• avoidcongestionsorworkermovementsnearmachinerythatarelikelytoincreasetheriskofinjury
• thelayoutshouldeliminateorminimisehazardousmovementsinrelationtooperation,cleaningormaintenance(e.g.blockage)
• wherewastematerialsaregenerated,thelayoutshouldincludespaceforstorageoraccumulationuntilcleared.Theyshouldnotbeallowedtoclutterwalkwaysorworkareas
• thelayoutshouldconsider‘trafficflow’byidentifyingthemovementsoftrucks,materialsandpeople.Bydefiningsimple,wellmarkedandwellunderstoodtrafficareasanddirections,thelikelihoodofpeoplecomingneardangerousmachinery,andthereforetheriskofinjury,canbereduced
• proximityofmovingpartsinrelationtoothermachineryorplantandfixturesinbuilding.
6.1.2 HousekeepingUntidinesscancauseslips,tripsandfalls.Injuriescanbeavoidedby:
• keepingworkareas,walkwaysandotheraccesspathsclearandclean.Theyshouldbeclearlymarked
• preventingspillswhichmaycauseslips.Designmachineryandworkprocessestominimiselubricationoillossorspillage.Cleanupspillsassoonaspossibleaftertheyoccur,andavoidanyoilyresiduesonthefloor.Providearoughanti-slipfloorwherethisisnotpractical.
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6.1.3 Work practicesAllprocessesrelatingtomachineryorplantshouldbedocumented.Inparticular,directionsaboutoperation,cleaning,maintenance,andproblemsthatmaybeencounteredshouldbeclearlystatedinawaythatensuresthesafetyoftheworker.Systemsshouldbeinplacethatpreventworkersfrombypassingguardingmechanisms.
Supervisionisessentialtoensurethatasystemofsafeguardsisusedcorrectly.
Changestomachinery(newplantormodifications)mayrequirechangestoexistingworkproceduresandprocessestoensuretheguardingdoesnotcreatenewproblems.Documentationandworkmanualsshouldbeupdatedatthesametime.
6.2 Work environmentThereareanumberofgeneraltypesofworkplacehazardsassociatedwithmachinery.Theseincludenoise,energy(electricityorhydraulics),manualhandling(lifting,repetitivemovements),substances(solvents,cleaners,chemicals),theworkenvironment(suchasconfinedspaces,lighting,ventilationandaccess),andtheactualplantandequipmentinuse.Therisksassociatedwiththesehazardsmustalsobeassessedandcontrolled.
6.2.1 DustAdustyworkplacecanbedangerous.Dustandotherairbornecontaminantscanhavedirectandseverelong-termeffectsonworkers’health,whichcouldincluderespiratoryproblems,skindisordersandevencancer.Dustcanalsocauseinjurybycloggingmachinery,inducingsuddenbreakdownsandobscuringmovingpartsandotherhazards.Thediscomfortcausedbydustontheskin,clothingandprotectiveequipmentcanalsocompromisesafety.
Somemeasuresforreducingtheriskofinjuryorillnessresultingfromdustinclude:
• installingadustcollectionsystemthatremovesdustfromtheenvironmentandcansavecleanuptime
• useofasimplelid,coverorshieldonsaws,augersandothermachinerytoreducedustlevels• housekeepingproceduressuchasfrequentcleaningordampingdown.
Suchguardingmayalsoreducethelevelofnoiseandimproveworkercomfortandproductivity.
6.2.2 LightingAmplelightingisneededfortheoperationofmachinerysothatmachinemovements,controlsanddisplayscaneasilybeseen.Poorlightingcanaffectpeoplebothphysicallyandpsychologically,causingeye-strainandtiredness.
Thefollowingissuesshouldbeconsideredwithrespecttolightingandmachinery:
• directionandintensityoflighting• contrastbetweenbackgroundandworkarea,applicabletobothworkenvironmentandcontrol
panels• colourofthelightsource• reflection,glareandshadows• thestroboscopiceffectoffluorescentlightingonmovingmachinerywhichmakesmovingparts
ofmachinerylookasiftheyarestopped• thestroboscopeeffectofrotatingbeaconsinmobileplantintheinternalenvironment.
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AS�680.�–�990/Amdt�–�990Interiorlighting–Generalprinciplesandrecommendationsprovidesmoreinformationinrelationguidanceonlightingquantities.Thisstandardshouldbeconsultedforadditionalinformation.
6.2.3 NoiseNoise,particularlyexcessivenoise,interfereswithconcentrationandcancauseoperatorstress(itselfasourceoferrors),whichcanleadtomistakes.Noisemayalsopreventaverbalwarningbeingcommunicated.TheWorkplaceHealthandSafetyRegulation�997includesprovisionswithrespecttonoiselevelsintheworkplace.Noiselevelsshouldbemeasuredtoensurecompliancewithrecommendedstandards.
Controlmeasuresfornoisyplantandmachineryinclude:
• providingsound-proofenclosures,whichmaybecombinedwithmachinesafeguarding• limitingexposureperiods• providingappropriate,properlyfittedhearingprotectionforoperatorsandotheraffectedworkers.
Itshouldbenotedthatincorrectlyselectedhearingprotectioncanartificiallydistracttheworker,causingthemtolooseconcentration.
Guardingcanbemadeaspartofthenoisesolution.Inmanyinstances,carefullydesignedguardingofmovingpartscanaidnoisereductionandhelpremovethestressassociatedwithprolongednoiseexposure.
6.2.4 Hot and cold environmentsAcomfortabletemperatureissafertoworkin.Accidentsaremorelikelytohappenifpeopleneedtoworkwherethetemperatureisoutsideacomfortableworkrange.Extremeheatorextremecoldmayalsoeffectmachineryoperationinvariousways.
Someofthecontrolmeasurestoconsiderwhenworkisconductedinhotandcoldenvironmentsinclude:
• providingappropriatepersonalprotectiveequipment,selectedwithconsiderationofthetaskstobeperformed.Incoldenvironments,bulkyinsulatedclothingmayrestrictmovement,reducemanualdexterityandincreaseentanglementrisks
• limitingexposureperiods• providingsufficientdrinkingwaterandairflowforoutdoorworkersorhotworkplaces• followingmanufacturersinstructionsorseekingtheiradviceaboutmachineoperationinextreme
temperatures.
6.2.5 VentilationSomeprocessesandmachinesgenerateheatandfumesduringoperation.Peopleworkingnearbymustbeadequatelyprotectedfrominhalingdangerousfumesandfromcontactinghotparts.
Tocontroltherisks,guardingshould:
• allowadequateairflow,forexample,throughameshguardsothatequipmentdoesnotoverheat• beinsulatedordistanceguardedtoreducetheriskofburns• includeductingifnecessarytoventhotairorfumesawayfromworkers• includefilters,ifrequired,toremovedangerousparticulatesfromtheair.
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6.2.6 Confined spacesConfinedspacescanbecreatedinoraroundmachineswhenguardingisremovedordeactivatedtoallowforcleaning,maintenanceoraccesstotheareasurroundingthemachine.
Confinedspacespresentarisktohealthandsafetyandcanpotentiallycontainmanyhazards,someofwhicharenotvisiblydetectable.
TheWorkplaceHealthandSafetyRegulation�997,part�5(Confinedspaces),section�45,dealswithusingconfinedspacesandidentifiesrelevantsectionsofAS/NZS 2865 – 2001 Safe working in a confined spacethatmustbecompliedwith.
AS/NZS 2865 – 2001 Safe working in a confined spacesetsouttheparticularrequirementsandprocedurestoensurethehealthandsafetyofallpeoplerequiredtoenterorworkinaconfinedspace.
AS4024.1 Safeguarding of machinery – General principlesalsoprovidesmoreinformationinrelationtotheenvironmentalfactorsdiscussedabove.Boththeregulationandthesestandardsshouldbeconsultedforadditionalinformation.
6.2.7 Electrical safetyDangeroussituationscanariseasaresultofthefailureofelectricalsafetycontrolsystems.Systemfailurecanbecausedbyseveralfactorssuchasenvironmentalconditions,suitabilityforthespecificsafetyapplicationandinsufficientsystemmonitoringandmaintenance.
The Electrical Safety Act 2002andtheElectricalSafetyRegulation2002providealegislativeframeworktopreventpeoplefrombeingkilledorinjuredandpropertyfrombeingdestroyedordamagedfromelectricity.TheActandtheregulationshouldbeconsultedforadditionalinformation.
AS1543 – 1985iscurrentlybeingreviewedandwillbecomeAS6024.1 – 200X Safety of machinery – Electrical equipment of machines Part 1: General requirements.Thisstandardwillproviderequirementsandrecommendationsfortheelectricalequipmentofindustrialmachineswithregardtosafetyofpeopleandproperty,consistencyofcontrolresponseandeaseofmaintenance.ThedraftisnottoberegardedasanAustralianStandardandshouldonlybeconsultedforadditionalinformationwhenStandardsAustraliahasreleaseditassuch.
AS4024.1 Safeguarding of machinery – General principlesalsoprovidesmoreinformationinrelationtothespecificrequirementsregardingoverallsystemdesigninrelationtoelectricalsafetycontrolsystems.Thisstandardshouldbeconsultedforadditionalinformation.
6.3 Minimising human error Humanorworkererrorisnotalwaystheresultofcarelessnessornegligence,butfollowsfromnormalhumancharacteristics.Thedesireforextraspeed,lessworkandmakingtaskseasier,aresomeoftheleadingreasonswhyguardsarebypassedorremoved.Also,peoplenaturallybecomeboredanddistractedwithrepetitiouswork,whichmaycauselossofconcentration.Designers,manufacturersandemployersshouldbeawareofthesefactorsindesigningmachinesanddevelopingsafeworkpractices.
Machineguardingsolutionsmusttakehumanissuesintoaccount,whichisanotherreasontogetthoseusingthemachineinvolvedindevelopingsolutions.Inthelongterm,acarefullyconsideredsolutionwillalmostalwaysprovetobelesscostlyandmoreefficient.
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Factorscontributingtohumanerrorinclude,butarenotlimitedto:
• vigilance• informationhandlingcapacity• ergonomics• psychologicalorculturalenvironment• habit• fatigue• leveloftraining.
Vigilance
Referstoaworker’sabilitytobealerttodangerorproblemsduringoperationandisahigherrequirementthan‘stayingawake’.Itimpliesactiveinteractionwithandawarenessoftheworkenvironment.Havingregularrestbreakshasthepotentialtoimproveworkperformanceandassistworkerswithremainingalerttoanydangerorproblemsthatmayariseduringoperation.Workerscannaturallybecomeboredanddistractedwithrepetitiouswork,whichmaycauselossofconcentrationandanoveralldecreaseinalertnessandawarenesstodangerorproblems.Jobrotationprovidesworkerswithvarietysothattheydonotbecomeboredwithrepetitivetasks,andthereforeincreasesthelikelihoodofworkersmaintainingahighlevelofalertnessandawareness.
Information handling capacity
Vitalinformationcanbeoverlookedifitispresentedtooquickly,orifitcomestogetherwithotherinformation(informationoverload).Ifapersonhastomonitormorethanone‘channel’ofinformationatanyonetime,theyshouldhaveaclearorderofpriority.
Ergonomics
Ergonomicsisthestudyofhumanandmachineinteraction.Pooroperatorcomfort(e.g.noattentiontothelocationofstools,buttons)cancontributetolossesofconcentrationandresultinerrors.
HB59 – 1994 Ergonomics – The human factor – A practical approach to work systems designproducedbyStandardsAustraliaprovidesmoreinformationinrelationtodesigningtheworkplaceandtheenvironmentinsuchawaythatthemostefficientuseismadeofhumancapabilities,withoutsucceedinghumancapacities.Thehandbookshouldbeconsultedforadditionalinformation.
Fatigue
Thesafeuseofmachineryismorethanattendingtoguarding.Longhoursofwork,shiftworkorlongperiodswithoutadequatebreakscanleadtolossofconcentration,slowreflexesandincreasedriskoferror.Excessiveheat,poorventilation,lightingandshiftworkalsocontributetofatigue,lossesofconcentrationanderror,allofwhichshouldbetakenintoaccountwhenlookingatmachineguarding.
The Workplace Health and Safety Queensland Fatigue Management Guideprovidesmoreinformationinrelationtofatigueandstrategiesonhowtobestmanageitintheworkplace.
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Psychological or cultural environment
Acorporatecultureofsafetycreatespositivebeliefsandvaluesregardingthemanagementofrisksintheworkplace,andconsequentlyreduceswork-relatedinjuryandillness.
Habit
Peoplecancontinueahabitualactivitydespiteindicationsofdanger.Clearlabellingofcontrolsandclear,simplewarningnoticescanhelp.Peoplealsogetusedtoaparticulararrangementofcontrols.Usestandardisedcontrolsasmuchaspossible,andensurethatlocationofthecontrolsisappropriate.Theactionusedtooperateacontrolshouldalsobecompatiblewiththeeffectonthemachinery,forexample,switchingacontroltowardstheleftmovesmaterialintothemachineinthesamedirection.Thiselementdeservesparticularattentionwhenconsideringthepurchaseofreplacementmachines,especiallyifthenewcontrolsarereversedorlocateddifferently.
Training
Itshouldnotbeassumedthatpeoplealreadyknoworcaninformallylearnaboutmachineryorplantsafety.Trainingmustbeprovidedtoworkersonanyrequiredpersonalprotectiveequipment,newlyintroducedequipmentormodificationstoexistingmachinery.Allpeoplewhosupervise,manageoroperatemachineryorplant,shouldreceiveappropriatetrainingandinstructionforhealthandsafety.Trainingshouldincludesafeoperatingproceduresandanyprecautionsthatmaybeneededtocontrolthehazardsofthemachinestheyoperate.
6.4 Registrable plantOwnersofplantlistedinschedule2oftheWorkplace Health and Safety Act 1995andschedule3oftheWorkplace Health and Safety Regulation 1997mustnotusetheplant,orpermittheplanttobeusedataworkplaceunlesstheplantisregistered.
OwnerswhowanttoregisterplantmustapplytoWorkplaceHealthandSafetyQueenslandontheprescribedform.Afeeispayableandacertificateofregistrationisissued,withregistrationbeingrenewedeachyear.Notificationofchangeofownershipofregisteredplantmustbegiven.
Registrableplantlistedinschedule3oftheRegulationincludesairconditioningunits,specifiedamusementdevices,buildingmaintenanceunits,coolingtowers,escalators,mobileelevatingcranes,towercranes,truck-mountedconcreteplacingboomsandspecifiedboilers,liftsandpressurevessels
6.5 Registrable plant designThedesignofplantlistedinschedule4oftheRegulationmustberegisteredwithWorkplaceHealthandSafetyQueensland.
AnapplicationforregistrationofdetailsofplantdesignwillberegisteredwithWorkplaceHealthandSafetyQueenslandifitismadeintheprescribedformandisaccompaniedbytheprescribedfeeandrepresentationaldrawingsoftheplantdesign.Anemployermustnotuseorpermittheuseof,anyplantlistedinschedule4unlesstheemployerpossessesacopyofthewrittennoticeoftheregistrationoftheplantdesignfromWorkplaceHealthandSafetyQueensland.
Registrableplantdesignappliestovehiclehoists,elevatingworkplatforms,specifiedcranesandhoists,lifts,escalators,domesticlifts,peoplemovers,amusementdevices(asclassified),andcertainboilersandpressurevessels.Applicabledesignstandardsarelisted.
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Section 7 - Further information7.1 Standards AustraliaStandardsAustraliadevelopsandmaintainsmorethan7000AustralianStandardsandrelatedpublications.Thesedocumentsareusedincountlessdailybusinesstransactionsandfacilitatetradebetweenindividuals,corporationsandnations.ToobtainfurtherassistanceinrelationtoAustralianStandards,StandardsAustraliacanbecontactedthroughtheirCustomerServiceCentre:
National Customer Service Centre
Telephone:�300654646Facsimile:�300654949OverseasTelephonecalls(02)820660�0OverseasFaxes(02)82066020Email:[email protected]:www.standards.com.au
7.2 Consulting engineersThereareanumberofconsultantswhocanofferadviceonsafeguardingmachineryorplant.Ifitisdecidedtouseaconsultant,shoparoundandmakesuretheconsultantisfullyconversantwithQueenslandlegislativerequirements,andthattheytakeanapproachtotheproblemthatisconsistentwiththeprinciplesidentifiedinthisguide.Askthemforevidenceofpreviousworkintheareaandcheckouttheworkforyourself,talkingifpossiblewithotheremployers.Smallemployerscanpoolwithotheremployersintheareainordertospreadthecosts.Thistypeofcooperationmakessenseasitsavestimeandmoney.
7.3 WorkersRemembertheworkforcewhenitcomestoseekingsolutions.Theyworkwiththemachineryandplanteverydayandtheycanoftennotonlyhelpbetteridentifyaproblem,butalsohelpwithdevisingthemostefficientandcost-effectivesolutions.Workplacesafetycommitteesorhealthandsafetyrepresentativesshouldbeinvolved,butevenifthesedonotexistattheparticularworkplace,workersshouldstillbeinvolved.Intheend,theyhaveadirectinterestinsafeguardingtheirownhealth.
Evenifexpertsorconsultantsarebroughtin,therewillbeaneedtoensurethatworkersareinformedandinvolved.Aguardmaylookfinefromanengineeringviewpoint,butitalsoneedstotakeaccountofworkercomfortandeaseofoperation.Workersareinthebestpositiontojudgetheeffectivenessofguardsonthemachinestheyareusing.
7.4 Industry associations and similar workplacesIndustryassociations,unionsetc.canbeusedtoobtainadditionalinformation.Theirexistingnetworksandcontactscanbeusefulinidentifyingspecificworkplacesthatperformsimilartypesofworkandthereforemaybeexperiencingsimilartypesofissuesinrelationtosafeguardingmachineryorplant.
7.5 Workplace Health and Safety QueenslandWhenconsideringmachineguardingneeds,orifunsureabouthowtohandleaproblem,WorkplaceHealthandSafetyQueenslandshouldbecontactedon�3003699�5.Issuesandoptionscanbediscussedwithaninspectororadviser.
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Appendix 1 – Machinery and plant hazard list
# Hazard Comments
Hazards, hazardous situations and hazardous events
1 Mechanical hazards�.� Generatedbymachinepartsorwork-pieces,caused,forexample,by:
�.�.� shape
�.�.2 relativelocation
�.�.3 massandstability(potentialenergyofelementswhichmaymoveundertheeffectofgravity)
�.�.4 massandvelocity(kineticenergyofelementsincontrolledoruncontrolledmotion)
�.�.5 inadequacyofmechanicalstrength
�.2 Accumulationofenergyinsidethemachinerycaused,forexample,by:
�.2.� elasticelements(springs)
�.2.2 liquidsandgasesunderpressure
�.2.3 theeffectofvacuum
�.3 Elementaryformsofmechanicalhazards
�.3.� crushinghazard
�.3.2 shearinghazard
�.3.3 cuttingorseveringhazard
�.3.4 entanglementhazard
�.3.5 drawing-inortrappinghazard
�.3.6 impacthazard
�.3.7 stabbingorpuncturehazard
�.3.8 frictionorabrasionhazard
�.3.9 highpressurefluidinjectionorejectionhazard
2 Electrical hazards, due to:2.� contactofpeoplewithliveparts(directcontact)
2.2 contactofpeoplewithpartswhichhavebecomeliveunderfaultyconditions(indirectcontact)
2.3 approachtolivepartsunderhighvoltage
2.4 electrostaticphenomena
2.5 thermalradiationorotherphenomenasuchastheprojectionofmoltenparticlesandchemicaleffectsfromshortcircuits,overloads,etc.
3 Thermal hazards, resulting in:3.� burnsandscaldsbyapossiblecontactofpeoplewithobjectsormaterials
withanextremetemperature,byflamesorexplosionsandalsobytheradiationofheatsources
3.2 healthdamagingeffectsbyhotorcoldworkenvironment
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4 Hazards generated by noise, resulting in:4.� hearingloss(deafness),otherphysiologicaldisorders(e.g.lossofbalance,
lossofawareness)
4.2 interferencewithspeechcommunication,acousticsignals,etc.
5 Hazards generated by vibration5.� useofhand-heldmachinesresultinginavarietyofneurologicaland
vasculardisorders
5.2 wholebodyvibration,particularlywhencombinedwithpoorpostures
6 Hazards generated by radiation6.� lowfrequency,radiofrequencyradiation,microwaves
6.2 Infra-red,visibleandultravioletlight
6.3 Xandgammarays
6.4 alpha,betarays,electronorionbeams,neutrons
6.5 lasers
7 Hazards generated by materials and substances processed, used by the machinery and by its constituent materials
7.� hazardsfromcontactwithorinhalationofharmfulfluids,gases,mists,fumesanddusts
7.2 fireorexplosionhazard
7.3 biologicalormicro-biological(viralorbacterial)hazards
8 Hazards generated by neglecting ergonomic principles in machinery design as, e.g. hazards from:
8.� unhealthyposturesorexcessiveeffort
8.2 inadequateconsiderationofhand-armorfoot-leganatomy
8.3 neglecteduseofpersonalprotectionequipment
8.4 inadequatelocallighting
8.5 mentaloverloadandunder-load,stress
8.6 humanerror,humanbehaviour
8.7 inadequatedesign,locationoridentificationofmanualcontrols
8.8 inadequatedesignorlocationofvisualdisplayunits(VDU)
9 Combination of hazards�0 Unexpectedstart-up,unexpectedover-run/over-speed(orsimilar
malfunction)from:
�0.� failure/disorderofthecontrolsystem
�0.2 restorationofenergysupplyafteraninterruption
�0.3 externalinfluencesonelectricalequipment
�0.4 otherexternalinfluences(gravity,wind,etc.)
�0.5 errorsinthesoftware
�0.6 errorsmadebytheoperator(duetomismatchofmachinerywithhumancharacteristicsandabilities,see8.6)
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11 Impossibility of stopping the machine in the best possible conditions
12 Variations in the rotational speed of tools
13 Failure of the power supply
14 Failure of the control circuit
15 Errors of fitting
16 Break-up during operation
17 Falling or ejected objects or fluids
18 Loss of stability / overturning of machinery
19 Slip, trip and fall of people (related to machinery)
Additional hazards, hazardous situations and hazardous events due to mobility
20 Mechanical hazards
21 Linked to the working position (including driving station) on the machine
22 Due to the control system
23 From handling the machine (lack of stability)
24 Due to the power source and to the transmission of power
25 Lack or inadequacy of visual or acoustic warning means
26 Insufficient instructions for the driver/operator
Additional hazards, hazardous situations and hazardous events due to lifting
27 Mechanical hazards and hazardous events
28 Electrical hazard
28.1 from lightning
29 Hazards generated by neglecting ergonomic principles
Additional Hazards, hazardous situations and hazardous events due to underground work
30 Mechanical hazards and hazardous events:
31 Restricted movement of people
32 Fire and explosion
33 Emission of dust, gases etc.
Additional hazards, hazardous situations and hazardous events due to the lifting or moving of people
34 Mechanical hazards and hazardous events
35 Falling of person from carrier
36 Falling or overturning of person carrier
37 Human error, human behaviour
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Appendix 2 - Dictionary of defined terms
Abrasion areas Abrasionareasinvolverelativelysmoothpartsoperatingathighspeed,e.g.therimofacentrifugebasketattheedgeofthecasingopening.Otherexamplesofabrasionareasincludetheperipheryofanabrasivewheel,beltsandingmachine,materialrunningontoareelorshaft,aconveyorbeltanditsdrumsorpulleys,andfast-movingropesorbelts.
Consequence Theoutcomeofaneventorsituationexpressedqualitativelyorquantitatively,beingaloss,injury,disadvantageorgain.
Cutting areas Cuttingareasmayinvolverotating,reciprocating,ortransversemotion.Thedangerofcuttingactionexistsatthepointofoperationwherefinger,armandbodyinjuriescanoccurandwhereflyingchipsorscrapmaterialcanstrikethehead,particularlyintheareaoftheeyesorface.Suchhazardsarepresentatthepointofoperationincuttingwood,metal,orothermaterials.Examplesofmechanismsinvolvingcuttinghazardsincludeallkindsofcuttingtools,bandandcircularsaws,boringordrillingmachines,planingandtenoningmachines,millingmachines,waterjetcutting,highenergylaseroredgesofmovingsheetmaterial.Thecuttingeffectmaybeaggravatedbythebodybeingunabletomoveawayfromthecutter.
Danger astateorconditioninwhichpersonalinjuryisreasonablyforeseeable.
Entanglement areas Entanglementareasoccursthroughbodilycontactthrough:
• contactwithasinglerotatingsurface,e.g.couplings,spindles,chucks,leadscrews,mandrels,bars,orrotatingwork-pieces
• catchingonprojectionsoringaps,e.g.fanblades,spokedpulleys,chainwheels,gearwheelsandflywheels,mixerandbeaterarms,spikedcylinders,beltfasteners,projectingkeys,setscrews,cotterpinsonshaftsorslatconveyors
• bycatchingbetweentwopartssuchasbetweencounter-rotatingparts(e.g.gearwheels,rollingmills),rotatingandtangentiallymovingparts(e.g.achainandchainwheel,apowertransmissionbeltanditspulley)orrotatingandfixedparts(e.g.revolvingmixerandmincingmechanismsincasingshavingunprotectedopenings)
• catchinginmaterialsinmotion,e.g.centrifuges,tumbledriersordoughmixers.
Fixed guards Permanentstationaryguardthatpreventsaccesstothedangerouspartsofmachinerybyenclosureorbyprovidingarigidbarrier.Mayalsototallyencloseamachine.Fixedguardsofferprotectiononlywhenproperlyfixedinposition,andshouldnotincorporateanymeansofretentionthatcreatestheimpressionoftheguardbeingsecurelyfixed,whentheyarenotsofixed.Fixedguardsmustbedesignedtorequireatoolforremovalandreplacement.
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Flying particles Thebodymaybepenetratedbyflyingobjects,ejectionofpartsofmachinery(e.g.flyingshuttleofaloom)orejectionofmaterial(e.g.moltenmetalejectionfromadie-castingmachine,sparksgeneratedinaweldingprocess).Injectionoffluidsthroughtheskincancausetissuedamagesimilartocrushingandcanbeconsideredinthiscategory.Examplesarecompressedairjets,dieselfuelinjectors,paintsprayersandhighpressurehydraulicsystems.
Guard Aphysicalbarrierthatpreventsorreducesaccesstoadangerpointorarea.
Hazard Somethingwiththepotentialtocauseharm.
Impact and crushing areas Impactandcrushingareasoccurwhenonepartofmachinerymovesagainstanotherwithapartofthebodyinbetweenegtheramofaforginghammer,counterweightsorthetoolsofpowerpresses.Thetraversingmotionofamachinerypartegthetableofamachinetoolandafixedstructurenotbeingpartofthemachinerymayalsocreatethistypeofahazard,asmayascissorhoistortable.
In-running nip point In-runningnippointsoccurontherotatingpartsofmachinery.Therearethreetypes:
• partsrotatinginoppositedirectionsandparalleltoeachother,typicallywherematerialmaybefedintoarollingmill,orwherethereareintermeshinggears
• betweenrotatingandtangentiallymovingparts,forexamplechainandsprocket,rackandpinion
• betweenrotatingandfixedpartswhichcreateashearing,crushingorabradingaction,asinspokedhandwheels,flywheelsandscrewconveyors.
Interlocking guard Physicalbarrierwhichisinterconnectedwiththepowerorcontrolsystemofthemachine.Theinterlockpreventsthemachineryfromoperatingunlesstheguardisclosed.Interconnectionsareusuallyeithermechanical,electrical,hydraulicorpneumatic,andprovideaneffectivesafeguardwhereaccesstothepointofoperationisrequiredbetweeneachcycleofthemachineorwhereregularaccessisneeded.
Lock-out/tag-out Procedurewhichcanincludevarioustypesoflocks,keysanddangertagseg.applyingalocktotheisolationswitch,aswellasadangertagwiththemaintenanceperson’snameonit.
Presence-sensing guard Therearetwotypes:
• laserguards—photoelectricsafetysystemsoperateontheprincipleofthedetectionofanobstructioninthepathtakenbyabeamorbeamsoflight.Theintangiblebarrieroperatedbythissystemmayconsistofasinglebeam,anumberofbeamsoflight,acurtainoflightoranycombinationoftheseasnecessarytoprovidetherequiredsafeguard.Ifthelightfieldisbroken,themachinestopsandwillnotcycle.
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Thisdevicemustbeusedonlyonmachineswhichcanbestoppedbeforetheworkercanreachthedangerarea
• lightbeams—usedinlaserguardingofmachinery.Maybeascanningbeamorbeams,oranumberoffixedbeams.Thelightmaybevisibleorinvisible,e.g.infra-red,andmaybecontinuousormodulated.
Risk Thelikelihoodthatdeath,injuryorillnessmightresultbecauseofthehazard.
Risk assessment Theprocessusedtodetermineriskmanagementprioritiesbyevaluatingandcomparingthelevelofriskagainstpredeterminedstandards,targetrisklevelsorothercriteria.
Risk priority Thelevelofimportanceplacedonariskwherethehighertheriskscorethehigherthepriorityofcontrollingtherisk.
Safeguarding Ameansofpreventingpeoplefromcomingincontactwithanyhazardouspartsofamachine.
Safety device Adevice,includingpresence-sensingdevices,otherthanaguardthateliminatesorreducesdanger.
Shear points Shearingactioninvolvesapplyingpowertoaslideorknifeinordertotrimorshearmetalorothermaterials.Shearpointsoccurwherestockisactuallyinserted,held,andwithdrawn.Partsofthebodymaybeshearedinthefollowingways:
• betweentwomachineparts,e.g.thetableofametalplaningmachineanditsbed,thebladeofaguillotine,nippointsbetweenconnectingrodsorlinksandrotatingwheels,oscillatingpendulummovements,orscissorliftsinshear
• betweenamachinepartandawork-piece,e.g.transfermechanisms,thetoolofabroachingmachine.
Stabbing points Stabbingpointsinvolvemovingpartsofmachineryorpieceofmaterial:
• flyingobjects,ejectionofpartsofmachineryorejectionofmaterial,e.g.timberejectedfromabenchsaw
• rapidlymovingpartsofmachineryorpiecesofmaterial,e.g.sewingmachines,drillingmachines.
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Appendix 3- Risk Assessment Form
Typeofmachine:................................................................................................................................................
Identification:......................................................................................................................................................
Hazard:………........................................................................................................................................................
• Onthefollowingchart,circlethemostlikelyharmtoapersoniftheriskhappens(alongthetop).• Next,circlehowoftenitcouldhappen(downthelefthandside).• Theriskpriority(score)isthenumberwherethetwointersect.
Risk Assessment Priority Chart
Likelihood:Howlikelycouldhappen?
Consequences:Howseverelycouldithurtsomeone?
EXTREMEdeath, permanent disablement
MAJORserious bodily injury
MODERATEcasualty treatment
MINORfirst aid only, no lost time
Very likelyCouldhappenfrequently
� 2 3 4
LikelyCouldhappenoccasionally
2 3 4 5
PossibleCouldhappenbutrarely
3 4 5 6
UnlikelyCouldhappen,probablyneverwill
4 5 6 7
Whatistheriskpriority?(score�-7fromtheabovechart)
• Ifyouscorea�,2or3–dosomethingnow–considerallapplicablecontrolmeasures.• Ifyouscore4or5–dosomethingassoonaspossible.• Ifyouscore6or7–doesnotneedimmediateattention.Choosecontrolmeasuresfromthehighestpossiblelevelinthefollowinglist:
Level 1: Eliminate the hazard
Level 2: Prevent or minimise the risk by one or a combination of:
Level 3: When exposure to the risk is not or cannot be minimised by other means:
• Substitutealesshazardousmachine• Modifythedesignofthemachine• Isolate themachinery• Introduce engineeringcontrols,
e.g.guarding
Introduceadministrativecontrols,anduseappropriatepersonalprotectiveequipment
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Control measures – action to take:Now:…………....................………………………………………………………………………………………..…………………………....................................................................................................................................................................................................................................................................................................................................................................Later (date and action):......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Inmanycases,guardingisthebestformofcontroltomanageexposuretorisksinvolvingtheuseofmachinery,particularlyinmanysmallerbusinesses.ThisRiskAssessmentFormcanbeusedtoprioritisetherisksidentifiedinaworkplace.
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Iden
tify
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Mon
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Appendix 4 – Risk Assessment Template
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Appendix 5 - Australian Standards
AustralianStandardsaretheacceptedstandardsforsafeguardingmachinery,plantandotherissues.Theyaredeveloped,publishedanddistributedbyStandardsAustralia.ContactdetailsforStandardsAustraliaare:
StandardsAustraliaLimited286SussexStreet,Sydney,NSW,2000GPOBox5420,Sydney,NSW,200�Telephone:+6�282066000
Email:[email protected]:www.standards.org.au
SomeofthemostusefulstandardsavailablefromStandardsAustraliarelatingtomachineguardingarelistedbelow.Thesestandardswerecurrentatthetimeofprinting.PleasecontactStandardsAustraliatoensurethatthesestandardsarestillcurrent.
Title Description
AS4024.�-�996Safeguarding of machinery
- General principles
Setsoutthegeneralunderlyingprinciplesformachineguardingandprovidesmeansforidentifyinghazardsandrisksarisingfromtheuseofmachineryduringallphasesofmachinelife.Methodsforeliminatingorreducingthesehazardsandrisks,forsafeguardingmachines,andforsafeworkingpracticesaredescribed.Guidelinesforassessingthesafetymeasuresneededinparticularcircumstancesareprovided.Itdoesnotprovideguidanceforsafeguardinganyparticularmachine.
AS4024.2–�998Safeguarding of machinery – Installation & commissioning requirements for electro-sensitive systems
– Optoelectronic devices
Specifiesrequirementsfortheinstallationandcommissioningofoptoelectronicdeviceswhicharetobeusedformachinerysafetyapplications.
AS4024.3–�998Safeguarding of machinery
– Manufacturing and testing requirements for electro-sensitive systems
– Optoelectronic devices
Specifiesrequirementsforthemanufactureandtestingofoptoelectronicsprotectivedeviceswhicharespecificallyusedformachinerysafetyapplications.
AS4024.4–�998Safeguarding of machinery – Installation and commissioning requirements for electro-sensitive systems – Pressure-sensitive devices
Specifiesrequirementsfortheinstallationandcommissioningofpressure-sensitivemats,floors,edgesandbarswhicharetobeusedformachinerysafetyapplications.
Iden
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of
haz
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Title Description
AS4024.5–�998Safeguarding of machinery
– Manufacturing and testing requirements for electro-sensitive systems – Pressure-sensitive devices
Specifiesrequirementsforthemanufactureandtestingofpressure-sensitivemats,floors,edgesandbarswhicharetobeusedformachinerysafetyapplications.
AS�2�9-�994Power presses - Safety requirements
Specifiessafetyrequirementsforthedesign,construction,operationandmaintenanceofpowerstampingpressesandbrakepresses.Incorporatesdetailsforsafeguardingpowerpresses,diedesignanddiesetting.Providesrecommendationsforoperation,maintenanceandinspectionofpresses,andthetrainingandsupervisionofoperators.
AS�473-�99�Guarding and safe use of woodworking machinery
Specifiesminimumrequirementsfortheguardingandsafeuseofpoweredmachineswhichcutorabradewood,woodproductsandlikematerials,tobeobservedbyemployers,trainers,employees,designers,makersandsuppliersofwoodworkingmachineryandotherpeoplehavinganinterestinwoodworkingmachineoperations.Chainsaws,andmachineryusedinthemillingofrawsawlogs,togetherwithdebarkersandlogpeelersarenotcovered.
AS�473.�-2000Wood processing machinery –Primarytimbermillingmachinery
Specifiessafetyrequirementsforthedesign,manufacture,guardinganduseofmillingequipmentusedfortheprimarymillingofsawlogsintogreensawntimberproducts.
AS�473.2–200�Woodprocessing machinery – Safety – Finishing machinery – Common requirements
Specifiesrequirementswhicharecommontoallclassesofwoodforthedesign,manufacture,guardinganduseofmachinesforthemanufactureofcomponentsforfurniturejoineryandthelike.Thestandarddoesnotapplytomachinesusedfortheprimarymillingof
AS�473.3–200�Woodprocessing machinery – Safety – Finishing machinery – Circular sawing machines
Specifiessafetyrequirementsforthedesign,manufacture,safeguardinganduseofcircularsawingmachinesusedinthemanufactureofcomponentsforfurniture,joineryandthelike.TobeusedinconjunctionwithAS�473.2,whichcontainsgeneralsafetyrequirements.
AS�473.4–200�Woodprocessing machinery – Safety – Finishing machinery – Bandsawing machines
Specifiessafetyrequirementsforthedesign,manufacture,safeguardinganduseofbandsawingmachinesusedinthemanufactureofcomponentsforjoinery,furnitureandthelike.TobeusedinconjunctionwithAS�473.2,whichcontainsgeneralrequirements.
AS�473.5–200�Woodprocessing machinery – Safety – Finishing machinery – Moulding machines and routers with rotating tool
Specifiesthesafetyrequirementsforthedesign,manufacture,safeguardinganduseofmouldingandroutingmachinesusedinthemanufactureofcomponentsforjoinery,furnitureandthelike.TobereadinconjunctionwithAS�473.2,whichcontainsgeneralrequirements.
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Title Description
DR0��45Wood processing machinery – Safety – Pt 6: Finishing machinery – Surface planers and thicknessing
Proposesthesafetyrequirementsforthedesign,manufacture,safeguardinganduseofsurfaceplanersandthicknessers,usedinthemanufactureofcomponentsforfurniture,joineryandthelike.TobereadinconjunctionwithAS�473.2,whichcontainsgeneralrequirements.
AS/NZS�677.�–�998Refrigerating systems
– Refrigerant classification
Specifiesasimplemeansofreferringtocommonrefrigerantsinsteadofusingthechemicalname,formula,ortradename.Italsoestablishesauniformsystemtobeusedinassigningtheproperreferencenumberandclassificationtorefrigerants.Thesystemforrefrigerantsclassificationisdefinedandphysicaldataofcommonrefrigerantslisted.
AS/NZS�677.2–�998Refrigerating systems
– Safety requirements for fixed applications
Specifiesrequirementsforthesafetyaspects,intermsofthedesign,construction,installationandinspectionofrefrigeratingappliances,systemsandancillaryequipmentintendedforuseorinstallationininstitutional,publicassembly,residential,commercialandindustrialoccupancies.Itappliestonewrefrigeratingsystems,toextensionsandmodificationsofexistingsystemsandtousedsystemsonbeingreinstalledandoperatedatanothersite.Italsoappliesinthecaseoftheconversionofasystemforusewithanotherrefrigerant.
AS�680.�–�990Interiorlighting
–Generalprinciplesandrecommendations
Specifiesgeneralprinciplesandrecommendationsforthelightingofinteriorsofbuildings.Primarilyrelatestointeriorsinwhichworkisundertakenandtakesintoaccountbothelectriclightinganddaylight.
AS�755–2000Conveyors - Safety requirements
Specifiesminimumsafetyrequirementsforthedesign,construction,installationandguardingofconveyorsandconveyorsystems,bothabovegroundandunderground.Itdoesnotapplytoplatformelevators,movingstairwaysorconveyorsspecificallydesignedfortheconveyanceofpeople.Providesrecommendationsforinspection,maintenance,markingandidentification,andthetrainingofoperators.
AS�788.�-�987Abrasive wheels - Design, construction and safeguarding
Specifiesrequirementsforthedesignandconstructionofabrasivewheelsandthemanufactureandinstallationofabrasivewheelsandancillaryequipment.Particularrequirementsaregivenfortheconstructionofguardsforallequipmentfittedwithabrasivewheelsandfortheconstructionofflangesforusewithabrasivewheels.Includessectionscoveringstandard(normal)maximumoperatingspeedsforalltypesofwheels.Extensivelyillustrated.
AS�788.2-�987Abrasive wheels - Selection, care and use
Specifiesrequirementsfortheapplicationandoperationofabrasivewheels.Includessectionsonthestorage,handlingandmountingofabrasivewheels,aswellasconditionsforusingspecialoperatingspeeds.Illustrationsofsuitableguardsandguardingdetailsareincluded.
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Title Description
AS�893–�977Code of practice for the guarding & safe use of metal & paper cutting guillotines
Outlinesthegeneralrequirementsforguarding,withspecificrequirementsfortheguardingofdifferenttypesofmachines.Fixed,interlocked,automaticandelectronicguardsareincluded.
AS/NZS22��.�–2004Safety of laser products
- Equipment classification, requirements and user’s guide (IEC 608825-1:2001, MOD)
Specifiesrequirementsandproceduresdesignedtoprotectpeoplefromlaserradiation.Intendedforapplicationbothbyusersandmanufacturersoflaserproducts.Itspecifiessafeworkinglevelsofopticalradiation,classifieslasersaccordingtotheirdegreeofhazardandsetsoutdetailedprotectiveandcontrolmeasuresappropriatetoeachclass.Astatementontheeffectoflaserradiationonbiologicaltissuesisgiveninanappendix,andotherappendicescovermaximumpermissibleexposures,calculations,amedicalsurveillancechart,andthedesignofwarninglabelsandsigns.Itisbasedon,butnotequivalentto,IEC825-�:�993.
AS/NZS22��.4–2002Safety of laser products - Laser guards
Providesrequirementsforlaserguards,permanentandtemporary,whichenclosetheprocesszoneofalaserprocessingmachine,andspecificationsforproprietarylaserguards.ThisstandardisidenticalwithandhasbeenreproducedfromIEC60825-4:�997.
AS/NZS22��.6–2002Safety of laser products - Safety of products with optical sources, exclusively used for visible information transmission to the human eye
Providesanadaptedhazardcategorisationschemeandspecificguidanceforthesafeuseofvisibleopticalsourcesthatareusedexclusivelyfortransmissionofinformationtothehumaneye.ThisstandardisidenticalwithandhasbeenreproducedfromIECTS60825-6:�999.
AS2359.9-�995Powered industrial trucks
- High-lift rider trucks - Overhead guards - Specification and testing
Specifiestherequirementsandtestingforoverheadguardsdesignedtoprotecttheoperatorfromfallingobjects,butnotfromtheimpactofafallingload.ThisstandardistechnicallyequivalentwithandreproducedfromISO6055:�979,includingErratum:�980.
AS2397–�993Safe use of lasers in the building and construction industry
Setsoutsafetyrequirementsfortheuseoflasersinthebuildingandconstructionindustry.ProvisionhasbeenmadefortheuseofClass3B(Restricted)laserswherethelevelofilluminationisappropriate.Itisintendedforuseasareferencebypeopleconcernedwiththeuseoflasersforalignment,levelling,controlandsurveytasksinthebuildingandconstructionindustry,andsupplementstherequirementsofAS22��relevanttoworkinthatindustry.Itdoesnotcoverthedesignandmanufactureoflasers,northeuseoflasersinotherapplications.
AS2939–�987Industrial robot systems - Safe design and usage
Specifiesrequirementsforthedesign,construction,safeguardingandinstallationofindustrialrobotsystems.Inaddition,requirementsaregivenforthetrainingofpersonnel.Recommendationsforthesafeprogramming,maintenanceandoperationofindustrialrobotsarealsoincluded.Thestandardisextensivelyillustrated.
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Title Description
AS266�–�983Vapour degreasing plant - Design, installation and operation - Safety requirements
Setsoutsafetyrequirementsforthedesign,constructionandinstallationofvapourdegreasingplantwithorwithoutultrasonicagitation.Providesalsorecommendedmethodsforthesafeoperationofsuchplantandprescribestheinspectionandmaintenanceproceduresrelevanttothesafetyofpeople.Appendicescoverarecommendedmethodforplantcleaning,andfirstaidinemergencies.Itdoesnotcoversurfacetreatmentprocessesoraqueousoralkalinedegreasing.
AS2958.0–2000Earth-moving machinery - Safety - General introduction and listing
ProvidestheintroductiontoandlistingofAustraliaStandardsgroupedunderthesubjectheading‘Safety’.
AS2958.�–�995Earth-moving machinery
- Safety - Wheeled machines - Brakes
Setsouttheminimumperformancecriteriaforservicebrakesystems,secondarybrakesystemsandparkingbrakesystemsforoperator-controlled,self-propelledearth-movingmachines.Appliestorubber-tyredbackhoeloaders,dumpers,excavators,graders,loaders,andtractorsortractorscrapers.Itincludesanappendixsettingoutrequirementsforin-servicetesting.
AS2958.2–�988Earth-moving machinery
- Safety - Guards and shields - Definitions and specifications
Givesdefinitionsandspecifiescharacteristicsofdifferentguardsandshieldstoprotectpersonnelfromaccidentalhazardsduetomechanical,thermal,chemicalorelectricalcauses.Coversbothrubber-tyredandtrack-typeoff-highwayearth-movingmachinery,butnotROPS,FOPSandcabs.
AS2958.3–�992Earth-moving machinery
- Safety - Roller compactors - Brake systems
Specifiesrequirementsforbrakesystemsthatarefittedtoself-propelledride-onrollercompactors.
AS37�0–�989Vibration and shock - Balancing machines - Enclosures and other safety measures
Specifiesrequirementsforenclosuresandothersafetymeasuresusedtominimisehazardsassociatedwiththeoperationofbalancingmachinesunderavarietyofrotorandbalancingconditions.Itdefinesdifferentclassesofprotectionthatenclosuresandotherprotectivefeaturesprovideanddescribesthelimitsofapplicabilityforeachclassofprotection.
AS3877–�99�Manipulating industrial robots
- Vocabulary
Definestermsrelevanttomanipulatingindustrialrobotsoperatedinamanufacturingenvironment.ItisidenticalwithandhasbeenreproducedfromISO/TR8373:�988.
AS3984–�99�Manipulating industrial robots - Performance criteria and related test methods
Describesmethodsofspecifyingandtestingtheperformancecharacteristicsofmanipulatingindustrialrobots.ThisstandardisidenticalwithandhasbeenreproducedfromISO9283:�990.
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Title Description
AS3985.�–�99�Manipulating industrial robots - Mechanical interfaces - Circular (form A)
Definesthemaindimensions,designationandmarkingforthecircularmechanicalinterface(formA).ThisstandardisidenticalwithandhasbeenreproducedfromISO9409-�:�988.
AS3986–�99�Manipulating industrial robots - Coordinate systems and motions
Definesandspecifiesthreerobotcoordinatesystems.ThisstandardisidenticalwithandhasbeenreproducedfromISO9787:�990.
AS3987–�99�Manipulating industrial robots
- Presentation of characteristics
Specifiesrequirementsforhowcharacteristicsofrobotsshallbepresentedbythemanufacturer.ThisstandardisidenticalwithandhasbeenreproducedfromISO9946:�99�.
AS/NZS4486.�–�997Playgrounds and playground equipment - Development, installation, inspection, maintenance and operation
Specifiesrequirementsforthedevelopment,installation,inspection,maintenanceandoperationofplaygroundsandplaygroundequipmenttoensureacontinuingleveloffunctionandsafety.Italsocontainsrequirementsforinformationtobesuppliedbythemanufacturer.
AS6�508.�–�999Functional safety of electrical/electronic/programmable electronic safety-related systems
- General requirements
Specifiesgeneralrequirementsforagenericapproachforallsafetylifecycleactivitiesusedinelectrical/electronic/programmableelectronicdevicesusedinsafety-relatedapplications.ThestandardisidenticalwithandhasbeenreproducedfromIEC6�508-�:�998.
AS6�508.2–200�Functional safety of electrical/electronic/programmable electronic safety-related systems
- Requirements for electrical/electronic/programmable electronic safety-related systems
Specifiesthesafetylifecycleactivitiesinsystemscomprisedofelectrical/electronic/programmableelectronicdeviceswiththerequirementsfortechniquesandmeasuresthataregradedagainstsafetyintegritylevels,fortheavoidanceandcontroloffaultsandfailures.
AS6�508.3–�999Functional safety of electrical/electronic/programmable electronic safety-related systems
- Software requirements
Specifiessoftwarerequirementsforagenericapproachforallsafetylifecycleactivitieswhenappliedtosafety-relatedsoftware.ThestandardisidenticalwithandhasbeenreproducedfromIEC6�508-3:�998.
AS6�508.4–�999Functional safety of electrical/electronic/programmable electronic safety-related systems
- Definition and abbreviations
Providesthedefinitionsandabbreviationsusedinotherpartsofthisseriesofstandards.ThestandardisidenticalwithandhasbeenreproducedfromIEC6�508-4:�998.
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Title Description
AS6�508.5–�999Functional safety of electrical/electronic/programmable electronic safety-related systems
- Examples of methods for the determination of safety integrity levels
Providesinformationontheconceptsandrelationshipofrisktosafetyintegritytogetherwithmethodsofdeterminingsafetyintegritylevels.ThestandardisidenticalwithandhasbeenreproducedfromIEC6�508-5:�998.
AS6�508.6–200�Functional safety of electrical/electronic/programmable electronic safety-related systems
- Guidelines on the application of AS 61508.2 and AS 61508.3
Specifiesthesafetylifecycleactivitiesinsystemscomprisedofelectrical/electronic/programmableelectronicdeviceswithguidelinesontheapplications,calculationsandmethodologiesasoutlinedinpart2andpart3ofthisstandard.
AS6�508.7–200�Functional safety of electrical/electronic/programmable electronic safety-related systems
Specifiesthesafetylifecycleactivitiesinsystemscomprisedofelectrical/electronic/programmableelectronicdeviceswithanoverviewofvarioussafetytechniquesandmeasuresasoutlinedinpart2andinpart3ofthisstandard.
AS/NZS2865:200�Safe working in a confined space
Setsouttheparticularrequirementsandprocedurestoensurethehealthandsafetyofanypeoplerequiredtoenterorworkinaconfinedspace.
HB6–�999Design standards for mechanical engineering students
ThishandbookcontainseditedextractsfromcurrentAustralianandBritishStandardsthatareofinteresttostudentsundertakingstudiesinmechanicalengineeringdesign.Itincludesextractsofstandardsconcerningdrives,structuraldesign,mechanicalhandlingequipment,andsafetyofmachinery,andisintendedtobeusedsolelyforthepurposeofstudentinstruction.
Australian Standards are available from:StandardsAustralia,55LittleEdwardStreet,SpringHill.
Phone (07) 3834 7460 or 1300 654 646 Fax (07) 3834 7461