Professional Documents
Culture Documents
Machine Guarding
Presented by:
TITO L. BRIZUELA, JR Safety Officer/Quality Assurance Engineer National Power Corporation Tiwi Geothermal Power Plant
Course Overview
Other Controls
Management Responsibility
Machinery must be reasonably well guarded. Built-In guards are always preferable to built-on guards. Temporary, makeshift and flimsy guards imply that management is not sincere in its efforts to protect the employee.
HAZARD IDENTIFICATION
Hazard Identification
What is a hazard?
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a Hazard is something which could cause injury. Unsafe workplace conditions or practices (dangers) that could cause injuries or illnesses (harm) to employees. a Risk is the likelihood of the hazard causing an injury, and the likely severity of an injury
Hazard/Risk
For example, a piece of plant or machinery may be a potential hazard; however, it may not necessarily pose a risk unless it is incorrectly guarded or the operator is inadequately trained.
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Danger Areas
Typically, the following 2 areas on machinery are dangerous, and can be a risk to anyone near the machine:
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Danger Areas
1. Parts which move or transmit power
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belts & pulleys flywheels & gear wheels shafts & spindles slides & cams chain & sprocket gears
Danger Areas
2. Parts that do the work
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tools & dies blades cutters saws drills and chucks rollers
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shear points drawing-in points impact and crushing areas entanglement areas stabbing points cutting areas abrasion areas flying particles
protrusions
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contact or entanglement with machinery trapping between machine and material or a fixed structure contact with material in motion being struck by material ejected from a machine release of potential energy
RISK ASSESSMENT
Complete the following chart to determine the level of risk for each hazard identified
If you score a 1 or 2, do something NOW. If you score a 3 or 4, plan to do something soon. If you score a 5 or 6, plan to review the risk in the future.
Elimination
Elimination means to completely remove the hazard, or the risk of hazard exposure. Removal of the hazard is the ideal control solution. For example: removal of a noisy machine.
Substitution
Substitution involves replacing a hazardous piece of machinery or a work process with a non-hazardous one. For example: the operator using a tool to load a press with parts instead of placing them in by hand automating a process to prevent the operator from entering a danger area
Engineering
If a hazard cannot be eliminated or replaced with a less hazardous option, the next preferred measure is to use an engineering control. Engineering controls may include: guarding machinery using enclosures (eg, enclosing a noisy piece of machinery) automating a process
Administration
Where Engineering cannot fully control a health and safety risk, administration controls should be used. Administration controls introduce work practices that reduce risk and limit employee exposure. They include: training employees in correct and safe operation developing Safe Operating Procedures (SOPs)
Administration
reducing the number of employees exposed to the hazard reducing the period of employee exposure developing and implementing lock-out procedures displaying appropriate warning signs
PPE
Personal Protective Equipment (PPE) should only be used when other higher order control measures are not possible, and only as a short term solution. Efforts to remove health and safety risks using Elimination, Engineering and Administration controls should be fully explored before PPE is implemented. Examples of PPE include: safety glasses gloves hearing protection
all guards should be correctly and securely fitted BEFORE operating a machine
machine guarding is vital to every workplace using machinery guards need not be complicated nor interfere with productivity
QUIZ: Let's assume you are the supervisor of a warehouse. Your five employees must lift and carry 85 pound sacks of grain repeatedly to a pallet during their eight-hour work shift. How can you reduce or eliminate the possibility of an injury from carrying the heavy bags?
What's the solution? Let's take a look at a few examples: Engineering Controls. Reduce the weight of the bags. Devise a conveyor belt system that eliminates the need to carry the bags. Administrative Control. Change the procedure so that two employees are required to carry a bag. Train and require
WORKPLACE HAZARDS
TYPES OF GUARDS
Selecting a Guard
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There are a number of different types of guards, all suited to particular purposes.
You must consider which type of guard is best suited for your needs.
Fixed Guards
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no moving parts
Interlock Guards
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have moveable parts that are interconnected with the control system usually electrical, mechanical, hydraulic or pneumatic interconnections machinery will not operate unless guard is closed less likely to slow production generally more expensive and require more checking and maintenance
Automatic Guards
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automatically moves into position as the machine, or cycle, is started guard movement/velocity may
create a hazard
Distance Guards
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A fixed guard that prevents access to a dangerous area through a barrier or fence
permanent simple
Presence-sensing Devices
Detect the presence of a person, or part of a person, in a defined area and prevents the dangerous parts of machinery moving while they are in that area
Barrier Fence
GUARD DESIGN
Guard Design
the primary function of a guard is to provide a physical barrier which prevents access to dangerous parts of a machine poorly designed or inappropriate guarding has often contributed to machinery injuries
Guard Design
design for easy removal and replacement makes tasks such as cleaning, machine adjustment or belt changes easier -
tool
hinged guards must be interlocked guard material must be of a good quality good design will aid dust and noise reduction
Guard Ergonomics
Reach Measurements - design and position guards to restrict access to danger points as follows:
Reach
Arm reach Elbow reach Wrist reach Vertical reach Finger reach
Guard Placement
Size of mesh or other opening in guard
less than 9mm 9 to 25mm 25 to 40 mm greater than 40mm
* distance from underside of guard to the floor shall not exceed 250mm
friction cutting
boring equipment
couplings
spindles fan-shafts ironing rollers
* must protect against loose clothing and long hair becoming caught in rotating shafts
Rollers
Roller Hazard
(Case
study) A man had his hand severely crushed and the skin stripped away from the wrist to the fingertips when it was drawn in between the inking rollers of a printing press. The man was attempting to remove a flake of paint off one roller while the press was running at high speed. A fixed guard was later installed.
Caught in Between
Roller Guarding
guards
On belt conveyors the most important danger points are the nip points.
Power Presses
Two Categories: power stamping presses brake presses * guards should prevent access to the trapping area at all times when the press is stroking
* it is mandatory that regular operational checks and maintenance is conducted and recorded
generally presence sensing devices (eg light curtains) are appropriate dead man type foot pedal actuator for each operator guard front and rear
Brake Press
WORKPLACE HAZARDS
OTHER CONTROLS
Other Safeguards
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Isolation Procedures
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all machinery should be fitted with a means of isolation from all energy sources (except those required for safety systems) isolators should be clearly identified and be capable of being locked if reconnection could place persons at risk (during maintenance, repairs, etc)
shall be prominent and readily accessible from all operator positions coloured red suitably marked
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Emergency Stop Buttons shall be mushroom head latch-in or lock-in manual reset type
lanyards, trip wires or similar devices are acceptable
require a manual reset before restarting not to be used for normal stopping not to be relied upon for isolation NOT an alternative to guarding
Access Provisions
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machinery design should allow routine adjustment, lubrication and maintenance without removing guards or extensive dismantling of components
lubrication and routine maintenance facilities should be incorporated outside the danger area wherever practical
Administration
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and records
Training
in safe working procedures, guarding and hazards of the machine they operate training records shall be kept
ERGONOMIC CONSIDERATIONS
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The following illustrations and tables may help you assess what sort of guarding is required and where it should be located (in order to keep a danger point on a machine safely out of reach). Where doubt exists in relation to the distances shown, measurements should be taken of the actual work place to ensure danger points are beyond reach.
A GOOD GUARD
Provides positive protection and prevents all access to danger zone during operation. Does not interfere with the operation of the machine, permits convenient and safe lubrication, adjustment and repairs.
Is strong and durable, fire and corrosion resistant
A GOOD GUARD
Does not have splinters or sharp edges and projections which may cause injury Is designed to prevent tampering and yet permit authorized removal and adjustment Does not interfere with the operator or cause eye strain or other discomfort.
Legislative Framework
Occupational Safety and Health Standards as amended describes how to provide health and safety in
workplaces and is a law that must be followed
Association and National Safety Council provide practical guidance to meet the legal requirements of the Act and Regulations and must be followed unless an equal or better solutions can be applied
THANK YOU