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NEBOSH DiplomaUnit C

Work equipment - general, machinery, and lifting and access

4 December 2017 10.00 – 11.30 hrs

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Introduction

• Webinar covering learning outcomes for C5 – C7

• Questions selected to stimulate understanding and consider answer techniques

• No idea what is on the exam!!!

– 10 elements / 44 learning outcomes / 11 questions

– Please prepare for ALL learning outcomes!!!

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Learning outcomes Element C5: Work equipment

• C5.1 Outline the criteria for the selection of suitable work equipment for particular tasks and processes to eliminate or reduce risks

• C5.2 Explain how risks to health and safety arising from the use of work equipment are controlled

• C5.3 Explain safe working procedures for the maintenance, inspection and testing of work equipment according to the risks posed

• C5.4 Explain the role of competence, training, information and supervision in the control of risks arising from the installation, operation, maintenance and use of work equipment

• C5.5 Outline the maintenance and prevention strategies when working with pressure systems

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What is meant by ‘work equipment’?

• Any machinery, appliance, apparatus, tool or installation for use at work (whether exclusively or not); and related expressions shall be construed accordingly– Tool box tools

– Single machines

– Laboratory equipment

– Lifting equipment

– Other equipment (ladders)

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Criteria for the selection of suitable work equipment for particular tasks and processes to eliminate or

reduce risks

Task, process, environment

Design, construction, adaptation

Energy sources

Intended location

Ergonomic, anthropometric factors

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Work Equipment Question

• Outline the factors that should be considered in ensuring the suitability of work equipment. (10)

• Complies with relevant aspects of PUWER / National legislation

• Conformity with standards• Construction of work equipment /

robustness / adaptation• Layout and operation of controls and

emergency controls• Does not create unacceptable risks• Adequate control of hazards • Capable of performing task as

intended• Maintainable in a safe condition• Isolation methods• Skill level of staff using it• Foreseeable misuse• Environment / working conditions

Risk Factors

Design

Construction

Use People

Environment

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How risks to health and safety arising from the use of work equipment are controlled

• Risk assessment

– Initial integrity, location and purpose

• Risks from incorrect installation, deterioration, exceptional circumstances

• Risk control hierarchy

– eliminating the risks

– hardware measures

– software measures

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Please post a response to the question below …

• What are four hazards / issues that may be associated with the maintenance of large items of work equipment?

• Hazards / issues associated with:– Confined spaces– Hot work– Use of contractors– Hazardous substances– Mechanical / electrical

work– Work above or below

ground– Work on plant– Lone working– Unfamiliar circumstances

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Safe working procedures for the maintenance, inspection and testing of work equipment according

to the risks posed

• Maintenance hazards and control measures

• Maintenance management strategies

• Factors to be considered in developing a planned maintenance programme for safety-critical components

• Statutory duties for maintenance

• Factors to be considered in determining inspection regimes – type of equipment; where it is used; how it is used

• Functional testing of safety-related parts– interlocks, protection devices, controls and emergency controls

• Advantages and disadvantages of non-destructive testing

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Test Advantages Disadvantages

Dye Penetrant Cheap and convenient

Superior to visual examination

For all non-porous materials

Surface defects only

Defects must be open to the surface

Preparation – use of cleaning chemicals

Radiography Virtually all materials

Permanent, pictorial, easily interpreted images obtained

Locates majority of internal defects

Safety hazards

Expense

Expertise

Orientation issues and thickness limits

Acoustic

Emissions

Testing

Immediate indication of risk of failure

Complete volumetric inspection

No disassembly or cleaning required

Flaws undetected if insufficient stress

Additional requirements in noisy environments

Other techniques (ultrasonic) required for quantitative results

Ultrasonic Precise location of internal and external defects

Most materials – Plastics, metals and timber

Expensive equipment

Dependent on a skilled operator and a power supply

Eddy Current Rapid detection of surface or sub-surface flaws

Can measure depth of shallow flaws

Conductive materials only

Ferromagnetic materials require treatment

Expertise required

Cannot find deep flaws

Rough surface finishes may interfere with results

Magnetic Particle

More sensitive than dye penetrant

Can also find sub-surface defects

Relatively low cost

Ferrous metals only

Cannot find defects at any significant depth

Requires power source – large currents required for large parts

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Answer planning …

• Outline the factors to be considered when developing a planned preventive maintenance programme for machinery (10)

• Statutory requirements• Manufacturer’s

recommendations • Operating environment• Age and condition• Breakdowns• Frequency • Maintenance tasks required • Safety critical parts• Timing of maintenance• Competence • Costs / benefits of PPM

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The role of competence, training, information and supervision in the control of risks …

• Training and competence • When training is likely• People having specific training needs• Relationship between competence and supervision• Specific training needs for certain hazardous types of work

equipment – Self-propelled, chainsaws, woodworking machines, power presses,

abrasive wheels

• Information required for safe use and operation– Conditions under which the work equipment may be used– Foreseeable abnormal situations and actions– Conclusions drawn from experience in usage

• Methods by which information / instructions are easily understood

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The maintenance and prevention strategies when working with pressure systems

• Definition of a pressure system • Types of inspection, frequencies, statutory basis• Mechanisms of mechanical failure

– excessive stress– abnormal external loading– overpressure– overheating– mechanical or thermal fatigue and shock– brittle fracture– creep– hydrogen attack– corrosive failure

• Prevention and testing strategies– design and construction, repair and modification, information and marking, safe

operating limits, written scheme of examination, maintenance and record keeping, competent persons

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Answer planning …

• Please think about the question below and list the key words you think might be useful to form the basis of your answer plan:

– Outline the technical and procedural issues that should be addressed by a designer/manufacturer and the eventual user in order to reduce the likelihood of an in-service failure of a safety critical component (10)

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Answer information

• Material from which it is made, its surface finish and the geometry of section changes that could produce areas of stress concentration

• Design specification– control of any heat treatment process– stress relieving takes place prior to machine finishing

• On assembly, procedures should be in place to prevent undue stresses being induced

• Correct torques and accurate alignment and balance• Strict quality assurance procedures• Programme of planned preventative maintenance• Condition monitoring (NDT)• Reliability data and fatigue life predictions

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Questions?

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Learning outcomes Element C6: Workplace machinery

• C6.1 Outline the principles of safety integration and the considerations required in a general workplace machinery risk assessment

• C6.2 Outline the principal generic mechanical and non-mechanical hazards of general workplace machinery

• C6.3 Outline the main types of protective devices found on general workplace machinery

• C6.4 Explain the principles of control associated with the maintenance of general workplace machinery

• C6.5 Explain the key safety characteristics of general workplace machinery control systems

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Principles of safety integration and general workplace machinery risk assessment

• SMSR 2008– designed and constructed to be fit

for purpose – eliminate or reduce risks

throughout lifetime – eliminate or reduce risks – protective measures where risk

cannot be eliminated– inform users of any residual risks – consider use and foreseeable

misuse – operator constraints due to

necessary or foreseeable use of PPE

– supplied with essentials for safe adjustment, maintenance, use

• Risk factors– Persons at risk– Severity / probability of injury– Need for access– Duration of exposure– Reliability of safeguards– Operating procedures– Personnel

• Purpose of CE marking and the relevance and limitations

• Selection and integration in the workplace

• Conformity assessments– Harmonised standards– Technical file– Declaration of conformity

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EN ISO 12100:2010

EN 574

EN 1088

EN 1760

EN 418

EN 954

EN 1037

EN 999

EN 972

EN 415

EN 746

EN 1114

EN 931

EN 692

EN 693

EN 60204

C Footwear

C Rubber and plastic

C Hydraulic presses

C Thermo-processing

C Mechanical presses

C Packaging

C Tannery machines

B1 Start-up

B1 Control

B2 E-stop

B2 Interlocks

B2 Mats & Edges

B2 Two-hand

B2 Electrical B1 Speeds

Type A Standard

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Principal generic mechanical and non-mechanical hazards

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Main types of protective devices found on general workplace machinery

• So far as is ‘practicable’– Provision of fixed guards

enclosing every dangerous part or rotating stock-bar

– Provision of other guards or protection devices

– Provision of protection appliances such as jigs, holders and push-sticks

• Supported by information, instruction, training and supervision

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Question …

• Explain the term 'fixed guard' in relation to machinery safety AND outline the factors to be considered in the design and use of fixed guards to ensure that persons are adequately protected. (10)

• Please consider how you might approach this question …

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Answer information …

• BSEN IS012100– guard that can only be opened or removed by tools or by destruction– protection against mechanical hazards

• infrequent or no access is required to dangerous parts

• Design features– material of construction (robust / ejected material / sight of process)– method of fixing– openings do not allow access to dangerous parts– noise and vibration

• Use– monitoring and supervision– safe systems of work for carrying out maintenance operations– information and training

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Principles of control associated with the maintenance of general workplace machinery

• Work equipment is shut down

• Not expose the person carrying out maintenance to a risk

• Protection of any person

• Consider

– Temporary guards

– Limited movement controls

– Crawl speed operated by hold-to-run controls

• Locate maintenance, lubrication and setting points outside the danger zones

• Safe systems of work

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Key safety characteristics of general workplace machinery control systems

• General controls– Starting– Normal stopping– Emergency stop

• Consideration of ergonomic principles

• Safe and reliable– No increased risk – Faults or damage – Loss of energy supply – Operation of any stop or

emergency stop control– Hardware or software

faults– Withstand operating

stresses– Human error during

operation must not give rise to hazardous situations

InputProcess

(Logic unit)

Sensor

Output

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Questions?

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Learning outcomes Element C7: Mobile, lifting, access and work at height

equipment

• C7.1 Outline the main hazards and control measures associated with mobile work equipment

• C7.2 Outline the main hazards and control measures associated with lifting equipment

• C7.3 Outline the main hazards and control measures associated with access equipment and equipment for working at height

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Mobile work

equipment

rollover, overturning, carrying passengers, unauthorised start-up, safe operating station,

overrun of speed, contact with wheels and tracks, falls of objects, moving parts, over-heating

energy sources (electrical, LPG, diesel)

self-propelled, towed, attached, pedestrian-controlled and

remotely-controlled

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Question …

• Identify:– (i) The factors affecting the

likelihood of an agricultural tractor overturning. (5)

– (ii) The measures that may be necessary to minimise the risk or mitigate the effects of a tractor overturn. (5)

• Part (i)– Angle of slope– Direction of travel on gradients– Uneven or soft ground– Speeding when cornering– Wheel width– Condition of tyres and tyre

pressures– Effects of trailers and attachments

• Part (ii)– Seat restraints– Roll over protection– Restricting use on steep gradients– Fitting counterbalance weights– Maintenance of tyres– Driver training

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Lifting equipment

cranes (mobile cranes, tower cranes, overhead

cranes)

hoists (gin wheel, construction site platform hoist) and lifts (passenger and

goods, scissor, vehicle inspection, MEWP)

Lifting Operations and Lifting Equipment Regulations 1998

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Main hazards and control measures associated with lifting equipment

• Collapse / failure due to overloading

• Overturns due to overloading and unsuitable ground conditions

• Load drops due to incorrect slinging or failure of tackle

• Hits structure, other vehicle, or person

• Hits overhead conductor or other overhead obstruction

• Load hits structure, vehicle or person

WorkplaceP

lant

Opera

tor

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Planning Lifting Operations

• Load and method of lifting

• Suitable crane

• Suitable accessories

• Positioning

• Site variables

• Erection and dismantling

• Risk assessment

• Method statements

– Tasks

– Safety precautions

– Pre-use checks

– Roles and responsibilities

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Please post your answer to the question below

• True or false?

– Lifting equipment for lifting people must be thoroughly examined at least once every three months.

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Question …

• National regulations such as LOLER 1998 (UK) specify fixed intervals between thorough examinations of lifting equipment but also include an option for thorough examination to be carried out in accordance with a written scheme.

• Outline the factors that a competent person would need to take into account when deciding whether less frequent examinations might be justified. (10)

• Answer information– Age / performance history – Insurance – Design standard– Quality of construction

materials– Manufacturer’s

recommendations– Compliance with

recommendations– Extent of use – Loads / environment in current

/ future use– Breakdown history– Modifications

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Questions?

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And finally … exam technique …

• Please …– Read the question

carefully

– Read the entire question

– Read the question again!

• Heed command words – bold, italics, CAPITALS

• Plan your answer

• 1.5 minutes per point

• Make a point to earn a point

• Start a new line for each new point

• Relate your answer to context / scenario

• Read your answer –check for logic, flow, number of points etc