NEBOSH International Certificate

Day 10

Programme for Today• Machinery Safety and Work Equipment. • Lifting Operations and Lifting

Equipment.• Transport Safety.

NEBOSH International Certificate

Machinery Safety and Work Equipment

Work EquipmentWhat is Work Equipment?

“ … any machinery, appliance, apparatus, tool or installation for use at work”.

Examples of work equipment are: hammer, photocopier, hoist, ladder and dumper truck.

Hazards of Machinery• Mechanical.• Non-mechanical.• From BS EN ISO 12100:

– Previously BS EN 292.– Previously BS 5304.

Hazards of Machinery• Mechanical hazards arise from direct interaction of

people w ith the machine itself.

• Non-mechanical hazards are associated w ith the use of machines, often the env ironment where the machine is located, the materials used and other aspects of the machine’s operation.

This illustration shows both types of hazard.

Mechanical Hazards• C rushing, e.g. hydraulic scissor lift.• Shearing, e.g. guillotine.• Cutting/sev ering, e.g. circular saw.• Entanglement, e.g. rotating drill chuck.• Draw ing-in and trapping, e.g. counter-rotating

rollers.• Impact, e.g. robot arm.• Stabbing/puncture, e.g. drill bit.• F riction/abrasion, e.g. moving belt sander.• High pressure fluid ejection, e.g. hydraulics.We will examine each in turn …

Crushing

Shearing

Cutting/Severing

Entanglement

Drawing-in and Trapping

Impact

Stabbing, Puncture and Ejection

Friction or Abrasion

Mechanical Hazards

Non-Mechanical Hazards• Noise. • Vibration. • Electrical.• Thermal - both high and

low temperatures.• Radiation - both ionising and non-ionising.• Hazardous materials and

substances.• Ergonomic.• S lips, trips and falls.

Hazards of Particular Equipment• Office Machinery

- Photocopiers, guillotines and document shredders.• Manufacturing and Maintenance Machinery

- Abrasive wheels/grinding machines, lathes, robots and presses.

• Agricultural and Horticultural Machinery- Cylinder mowers, Strimmers and chainsaws.

• Retail Machinery- Compactors and checkout conveyor systems.

• Construction Machinery- Cement mixers and circular saws.

Can you think how they are hazardous?

Principles of Machinery SafetyMethods of ProtectionThe hazards should be identified by means of risk assessment. A hierarchical strategy of protection should be used.Robust phy sical barriers are the most effective. Reliance on training only, is the least effective.

Methods of Protection• Safety by design:

– Eliminate or reduce hazards at the design stage.

• Safeguarding:– Add guards or other protection

dev ices to the machine.• Information:

– So end user can apply procedural controls.

Safety by Design

Guarding

• Hierarchy of control:– F ixed guards.– Other guards or

protection dev ices.– Protection appliances.– Information, instruction,

training and superv ision.

• The principle is to:– prev ent access to dangerous parts, or– stop the movement of dangerous parts.

Fixed Guards• Must be secured in place.• Must require a tool to remov e

the fixings.• Fixed enclosing guards.• Fixed distance guards:

– Reaching in distances are dictated by BS EN 294.

Fixed Enclosing Guard

Fixed Enclosing Guard on a Belt Drive Mechanism

Fixed Distance Guard

Fixed Distance Guard o n a Co nveyor Mechanism.Note the tunnel guard on the conveyor.

Fixed Guards

Other Guards -Interlocked Guards

• Must prevent movement of the dangerous part(s) when guard is open.

• Must not allow access to the dangerous moving part(s) until mov ement has stopped.

• Must not allow movement of the dangerous part(s) until the guard is in safe condition.

Interlocked Guards

On/off switch interlock activator

Interlock a nd Actuator on a Sliding Guard

Perimeter Fence Guard

On/off switch interlock activator

Perimeter Fence Guard with Fixed Pa nels and Interlocked Access Door

Interlocked Guard

Interlocked Gu ard Being Used on a Pillar Dril l

Automatic/Sweep Away Guards

Self-Adjusting Guards

ATypical Arrangeme nt of a Self-Adjusting Guard

Adjustable Guards

Circular Saw with Adjustable Guar d

Protection Devices• Trip wands.• Photoelectric guards.• Pressure mats.• Tripwires.• Two-hand controls.• Protective appliances:

– Jigs and push sticks.

Trip Wand

Photoelectric Device

Photoelectric Device Fitted to a Press Brake

Tripwire Device

Suitable Design of T ripwire

Two-Hand Control

Protective AppliancesJigs and Push Sticks

APush Stick Being Used on a W ood Thickener

The Protection Hierarchy - cont inued

• Personal Protective Equipment.• Information, instruction, training and

supervision. • Safe systems of work.• Permit systems.• Isolation.• Must cover all types of work - use, setting,

cleaning and maintenance.

ResponsibilitiesResponsibilities are held by:• Employ ers.• Self-employed.• People who have control of

work equipment:– Client who lends a piece of work equipment to a

contractor.– Hire company.

• Users.

Supply of Machinery

• Meets the ‘essential health and safety requirements’.• Appropriate conformity assessment has been carried out.• A technical file has been prepared.• A declaration of conformity or declaration of incorporation

has been issued. • In EU, a CE mark has been affixed.• Standards often country specific, e.g. BSI or ANSI.• It is, in fact, safe.

Principles

Principles of Safe Work Equipment Suitability of Work EquipmentSelection must take account of:• Construction and suitability for the work.• The place where it will be used.• The purpose for which it will be used.

Maintenance and InspectionsWhere this affects health and safety then:• It must be carried out by a competent person.• It is recommended that this is recorded where not

mandatory.

Principles of Safe Work EquipmentInspections

• Where safety depends on the standard of installation, it must be inspected:

– Before be ing put int o serv ice.– When mov ed t o a new sit e or loc ation.

• Where failure, due to deterioration, could lead to significant risk, it should be inspected:– At suitable inte rva ls.– When exceptional ci rcumstances occ ur.– Inspections r equired must be recorded. Rec ords should include:

• Deta ils o f equipm ent and date of inspect ion.• Who car ried out t he ins pect ion.• Faults identif ied and act ion ta ken.

– Evidence o f inspect ions m ust be ava ilab le f or equipment for hire.

Principles of Safe Work EquipmentWork Equipment with Specific HazardsWhere maintenance involves a specific risk:• It must be restricted to trained and designated staff.

Information and Instructions• Supervisory staff must have written instructions on

acceptable working practices for the equipment, and action to be taken in abnormal situations.

Training for Operators• Is now extended to those supervising operations.• It emphasises the need to train young people for

specific operations.

Principles of Safe Work Equipment

Protection Against Specified HazardsAimed at reducing the risk associated with specific operations, e.g. dust or fumes being generated by a process.

Protection against High or Low TemperatureProvision to prevent employees coming into contact with high or low temperatures.

Dangerous Parts of MachineryReminds employers of obligations to guard machinery, and where not feasible, to introduce alternative controls.

Principles of Safe Work Equipment Starting ControlsEquipment should not be able to restart on its own after any form of stoppage.Stop Controls and Emergency Stop ControlsShould be readily accessible.

ControlsAll control should be clearly visible and identifiable.Isolation from Sources of Energy• Equipment/components should be able to be isolated from sources of energy. • Where more than one person is at work within an area then facilities to ‘lock off’ should be fitted.

Principles of Safe Work Equipment

Are an additional precaution, not asubstitute for guarding.• Can be buttons or cables.• Must be suitably positioned.• Must latch.• Must require reset and restart at the

control panel.

Emergency Stops

Principles of Safe Work EquipmentStability and Lighting• Fixed equipment should be prevented from moving.• Systems to be introduced to ensure

mobile equipment is operated within its limits of stability.• Lighting should be adequate for the task.

Maintenance Operations• Should not in themselves put employees at risk.

Markings and Warnings• All controls to be marked.• Warning signs to be provided.

NEBOSH International Certificate

Mechanical Handling Hazards and Control

Mechanica l Handling Equipment

• Manually-propelled or powered devices.

• Mechanically-powered dev ices.

Mechanical Equipment may be div ided into two groups:

Lifting equipment is defined as:“… any equipment used for lifting or lowering loads, including any attachments and accessor ies”.

Mechanica l Handling EquipmentManually-propelled or powered devices include trolley s, sack trucks and pallet trucks.Mechanically-powered devices include types of F LTs, conveyors, lifts and hoists, and cranes.We will also consider lifting accessories:• Chains.• Slings.• Shackles.• Eye bolts.

Mechanica l Handling EquipmentForklift Trucks

Pedestrian Pallet Stacker Pedestrian Counterbalanced Truck

Four-directional Truck

Reach TruckSide Loading Truck

Mechanica l Handling EquipmentPedestr ian Operated Load Moving Equipment

Cage d Pl at form TruckTw o- w he ele d Pl at f orm Tr uc k

Sack Tr uc k

Palle t Truck

Mechanica l Handling EquipmentLifts and Hoists

Cantilever Hoist

Cranes - three types:

Mobile Cra neTower Cra ne

A Gantry Crane is sho wn next.

Mechanica l Handling Equipment

Overhead Gan try Crane

Mobile Cranes

Hazardsand

Controls

Hazards- Toppling over due to being unbalanced.- Jib swinging out of control.- Load striking something while being moved horizontally.- Load falling.

Mechanica l Handling Equipment

Safe Operations- SSW.- Capacity.- Site conditions.- The lift.

Lifting Accessories

Mechanica l Handling Equipment

Strength and stability:• Of the lifting equipment and of

lifting accessories.

Equipment for lifting people:• Prevent the person from being

crushed, trapped or struck.• Prevent them from falling.

Mechanica l Handling EquipmentPosition and Installation

• Load striking another person.• Load drifting, falling freely or being

released unintentionally.Marking

• SWL in each configuration.• On lifting accessories for safe use.

Mechanica l Handling EquipmentOrganisation of Lifting Operations• P lanned by competent person.• Appropriately superv ised.• Carried out in safe manner.

No requirement for risk assessment - because?

Mechanica l Handling Equipment

Thorough Examination and Inspection• Thorough examination is usually done by a

third party .• Inspection is less detailed and is usually done

by an in-house employ ee.• Both parties must be a competent person.

Initial Thorough Examination• On all lifting equipment, before it is put to first

use by an employer, unless:– It is new and has appropriate declaration of

conformity.– It is second-hand, but has an in-date report.

• On all lifting equipment where the installation of the equipment affects its safety.

Thorough Examination• On installation when moved to

a new site where conditions may affect safety, e.g. tower crane at new site.

• Periodically.• Follow ing exceptional

circumstances.

Periodically

• Annual for lifting equipment not used to carry people.

• Every 6 months for equipment used to carry people.

• Every 6 months for lifting accessories.• As dictated by a scheme of examination

written by a competent per son.

Exceptional CircumstancesWhat would these be?

• Contact w ith structures, serv ices and people.

• Overturning.• Collision w ith other vehicles or

pedestrians.• Falling from vehicle.• Entanglement in dangerous parts. • Explosions during battery

charging and ty re inflation.

Types of Accident

Exam Question(a) Descr ibe, by means of a labelled sketch,

a chemical indicator (stain detector) tube suitable for atmospheric monitoring.

(4 marks)(b) List the main limitations of chemical

indicator (stain detector) tubes.(4 marks)

(Source: NEBOSH)

The Practical ExamHow is it run?

What do you have to do, to score well?

Any questions?

NEBOSH International Certificate

Transport

Management of Transport• Control the workplace.

• Control the people.

• Control the vehicles.

Transport - WorkplaceWorkplace management rev olves around the requirements of the HSE Workplace Regs:

• Maintenance.• Construction of floors and traffic routes.• Organisation of traffic routes.

Transport - People

• Operator selection.

• Operator training.

• Health screening.

• Supervision and discipline.

Transport - Vehicles

• Selection.

• Maintenance.

• Control of use.

Forklift TrucksHazards of FLTs:• Overturning. • Falling from loading bays, etc.• Loads falling. • Vehicles striking people. • Vehicles striking building,

plant or equipment.• Use by unauthorised persons.• Refuelling.

Typical Stores

CounterbalanceFLTs

FLTs - Lateral Instability

FLTs -Longitudinal Instability

FLTs - Do’s and Don’ts

FLTs - Driver Training• Basic training:

– Skills/know ledge needed for safe operation.• Specific job training:

– Know ledge of the workplace and special techniques.• Familiar isation training:

– On-the-job under close superv ision.• Managers must have:

– Basic training and knowledge of the vehicle.– Training and information on risk assessments.– Knowledge of any w ritten systems of work.

FLTs - Driver Health• Full movement of the trunk.• Normal agility.• Normal hearing.• 12/6 v ision:

– If spectacles should be worn, they must be worn at all times.

• Epileptic seizure, heart problem or stroke:– Doctor certifies a return to work.

• Stable mentality.

FLTs - Rated Capacity PlateAll fork lift trucks must display a rated capacity plate, which will show the actual weight at a certain distance from fork face that the truck can lift. For example:

Weight Load Centre Mast Height2500 kgs 600 mm 4.5 metres

FLTs - Hazards Associated with Fue lsBattery charging:• Hydrogen gas:

– Ventilation, fire equipment, no smoking and signage.• Sulphuric acid:

– Protective clothing, spillage procedure, clean water, first-aid and topping up procedure.• Electricity :

– Insulated tools, safe charging procedures and isolation.

Transport - Falls from Vehicles