Moving and Rotating Equipment

Critical Task Safety Training

Moving and Rotating Equipment

Version: 3

Issued : September 2013

Important note

Why is important to provide physical protection of rotating and moving

machinery?

During the past couple of years a large percentage of the injuries

experience at Mondi operations are associated with rotating and moving

machinery. Many of these have resulted in serious lost time injuries, as

well as amputations.

In 2012 an operator pulled into a horizontal boring machine that was not

suitably guarded and he failed to switch off the equipment before

coming into contact with the rotating parts.

Moving and Rotating Equipment September 2013 Page 1

Examples

The following are some methods of providing protection machinery safeguarding:

Fixed Guards;

Interlocking Guards;

Inspection Guards;

Automatic Adjusting Guards;

Manual Adjustable Guards;

Barricading;

Fencing.


Safety Protection

The following are various methods of additional protection used:

Light Sensors;

Weight Sensors;

Double Hand Controls;

Control panels installed at safe distances;

Gates and Shields;

Restraint Devices;

Automatic Feed Equipment;

Semi Automatic Feed Equipment;

Robots;

Assistance Tools


Site specific example


Important

Each operation must add in some slides showing safety

systems used on site to prevent access to moving and

rotating equipment.

Risk of Incidents

The following are examples of what could contribute to an incident occurring:

Close contact to the nip points of moving machinery;

Close contact to rotating machinery and the nip points;

Poor housekeeping resulting in tripping around machinery;

Long hair and loose jewellery being pulled into rotating machinery;

Loose Clothing being pulled into rotating machinery;

Working on moving or rotating machinery;

Failure to isolate the power source before working on machinery;

Making Adjustments to operating machinery;

Conducting cleaning and clearing of blockages on operating machinery;

Moving under or over conveyor belts;

Cleaning of rotating rollers on printing and paper machines;

Failure to replace machine guarding after maintenance work;

Insufficient design of machine guarding


Nine Safety Rules to Live By

Rule Number One: Obtain authorization before overriding or disabling protective equipment Working in or around moving or rotating machinery can pose a threat to your

safety when exposed to unprotected nip points

In order to keep you safe at all times you shall:

Avoid engaging in any work that exposes you to unguarded nip points

Obtain authorization from person in charge before overriding or disabling a safety

device.

Report any damaged or missing safety-protective equipment


Serious Incident – 2012 Case Scenario


August 2012

On 3 August 2012, an employee was injured after being

caught by the rotating parts of a horizontal boring

machine.

An employee was conducting machining work with the use

of a horizontal boring machine at one of the workshops of a

Mondi operation.

At some stage during the machine activity the employee

needed to conduct a measurement of the equipment that

he was machining.

In order to measure the equipment he operated the boring

machine accordingly to separate the rotating cutting tool

and the equipment from each other. He then approached

the equipment and placed the measuring device into the

housing of the equipment. However the employee failed to

switch the equipment off prior to conducting the

measurement.

As result he was pulled into the machine and suffered

multiple injuries of the leg and arm

Always switch lathes and

boring machines off before

taking measurements,

inspecting the work and or

adjusting tools and work

pieces.

Man versus Machine –

Machine Always Wins

Date

Case Scenario Two


Important

Each operation must add in at least one case

scenario of an incident or close call involving

poorly completed or non adherence to permit to

work conditions

Operation of Equipment

Never operate any equipment if you have not been trained in the safe operating

procedures.

Always inspect the equipment prior to use to ensure the following: Guards and all fixings are in place and fitted correctly;

Protective devices and emergency stops are in working order;

Equipment is safe and does not pose any risk of injuries to any person,

Never operate the equipment if safety equipment is missing or damaged,

including: Protective Devices;

Emergency Stop Switches;

Machine guarding;

Interlocking devices


Maintenance of Equipment

Always isolate and lock out the energy sources prior to removing the guarding and

conducting cleaning or maintenance work.

Ensure clear communication is provided prior to commencing with maintenance

work:

Inform operator that equipment will be isolated and may not be operated;

Ensure requirements of Permit to Work are adhered to.

On completion of maintenance and repairing work always ensure:

All Machine guards are replaced and secured correctly;

All safety devices are in a safe working condition.


Maintenance of Equipment

Do not start the equipment if it is unsafe or poses a risk of injury.

Maintenance staff to ensure equipment /area is handed over in a safe condition: All guards and safety devices checked and in working condition

All equipment and material from maintenance work has been removed.

Operators should inspect the equipment and area before starting machine,

including : All hoses are rolled up and stored safely to prevent tripping hazards;

All spillages of oil or chemicals have be removed;

All spares and tools have been removed;

All guarding and safety devices are replaced and in good working condition.


Exceptions

There are occasions that work has to be conducted on rotating and moving

equipment in order to make adjustments, setting up , jogging, etc. however the

following must be in place:

Risk assessments have been conducted prior to the work being conducted;

Safe work procedures are developed and used in training;

Only authorise persons who are trained and deemed competent may conduct the

work;

Work Is conducted at crawl speed;

Work Should be supervised and conducted under Permit to Work Conditions.


Site specific example


Important

Each operation MUST include slides on the site specific

procedures regarding the work on running equipment.

Protection from All Sides

Machine Guarding must provide protection from all nip point and moving parts:

Front face, top and bottom, sides and rear side.


Side B

otto

m

To

p

Side

Examples of Fixed Guarding


Practical Examples


Practical Discussion

The supervisor MUST provide some examples of the fixed

guarding used on site

Examples of Distance Guarding


Practical Examples



The supervisor MUST provide some examples of the

distance guarding used on site

Examples of Safety Devices and Stops


Interlocking Device Emergency Pull Cable

Emergency Stop Interlocking Device

Emergency Pull Cable

Emergency Stop

Practical Examples



The supervisor MUST provide some examples of the safety

devices and emergency stops available on site

Bench and Pedestal Grinding Machines

To ensure maximum safety with bench and pedestal grinders the following must

be in place:

Securely mounted to falling over or moving during operation;

Tool rests fitted to the front of the grinding wheels;

Tool rests mounted as close to the grinding wheel as possible;

Side covers are securely in place providing protection to the sides of the grinding

wheels;

Grinding machines are inspected at regular frequencies to ensure the following:

- Equipment Safe

- Guards and tool rests securely in place

- Condition of grinding stones


Manual Intervention

Manual Intervention with Moving and Rotating Equipment is prohibited.

Operations must provide tools to be used for leaning of rolls.

Equipment should be stopped before any cleaning activities commence.

Procedures must be clear that persons may not place hands on moving and rotating

equipment.


Practical Examples



The supervisor MUST demonstrate the tools to be used for

cleaning of the rolls.

Horizontal Turning Machine Safety

To ensure maximum safety with lathes the following must be in place:

Guards placed over revolving chucks:

Guards over chucks fitted with interlocking devices;

Back plates fitted to lathes to protect persons passing;

Emergency Stop Buttons fitted and in close reach;

Guards covering protruding revolving objects


Competence Test

General Safety Issues (Pass Mark 100%) Site Specific Issues (Pass Mark 100%) There are three different test issued at random



FORWARD - LOOKING STATEMENTS

It should be noted that certain statements herein which are not historical facts, including, without limitation those regarding expectations of market growth and developments;

expectations of growth and profitability; and statements preceded by “believes”, “expects”, “anticipates”, “foresees”, “may” or similar expressions, are forward-looking

statements. Since these statements are based on current knowledge, plans, estimates and projections, they involve risks and uncertainties which may cause actual results to

materially differ from those expressed in such forward-looking statements. Various factors could cause actual future results, performance or events to differ materially from those

described in these statements. Such factors include in particular but without any limitation: (1) operating factors such as continued success of manufacturing activities and the

achievement of efficiencies therein, continued success of product development plans and targets, changes in the degree of protection created by Group’s patents and other

intellectual property rights, the availability of capital on acceptable terms; (2) industry conditions, such as strength of product demand, intensity of competition, prevailing and

future global market prices for the Group’s products and raw materials and the pricing pressures thereto, financial condition of the customers, suppliers and the competitors of the

Group, potential introduction of competing products and technologies by competitors; and (3) general economic conditions, such as rates of economic growth in the Group’s

principal geographical markets or fluctuations of exchange rates and interest rates.

Mondi does not

a) assume any warranty or liability as to accuracy or completeness of the information provided herein

b) undertake to review or confirm analysts’ expectations or estimates or to update any forward-looking statements to reflect events that occur or circumstances that arise after the

date of making any forward-looking statements.

Contact Person:

Brian Darlington

[email protected]

Moving and Rotating Equipment

Documents

Transcript of Moving and Rotating Equipment