01_SS537Pt12008COPforSafeuseofmachinery

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SS 537 : Part 1: 2008CODE OF PRACTICE FOR

Safe use of machinery

Mr Edwin Yap

President

Singapore Institution of Safety Officers

Managing DirectorESIS Asia Pacific Pte Ltd

ESIS Inc (Malaysia Branch)

ACE EHS Consulting (Shanghai) Co Ltd

Contents of SS 537

1. Definitions

2. Principles of risk assessment and reduction

3. Hazard management

4. Safeguards and safety devices

5. Installation considerations

6. Maintenance

7. Safe Work Practices



Introduction – Mechanical Hazards

SS 537: Part 1: 2008 – to provide guidelines on:

Methods for safeguarding dangerous parts of machinery

Enhancing safety in the use of machinery

Basic requirements on the design and manufacturer of machinery

Safety and health issues – installation, testing, maintenance and servicing

Dangerous moving parts that need safeguarding:

The point of operation is the point where work is performedon the material, such as cutting, shaping, boring, orforming of stock

These components include flywheels, pulleys, belts,connecting rods, couplings, cams, spindles, chains,cranks, and gears

All other moving parts of the machine which move while the

machine is working.

Introduction



Principles of Risk Assessment &Reduction

Strategy for selecting machine safety measures:

Identify the hazards and assess the risk

Eliminate the hazards by inherently safe design

Where not practicable:

Use of safeguards

Use of safe work practices

Use of personal protective equipment

To be carried out before:

Work commences on any machinery

Establishing and implementing SWP

Collect useful information from:

Design drawings

Limits of the machinery

Requirements for the life phases of the machinery

Information concerning power supply

Incident or accident history

Information about damage to health

Risk Assessment



Reference to WSH (Risk Management) Regulations

To examine hazards associated with machinery

Include risk analysis and risk evaluation

Risk analysis – provides information required for riskevaluation

Examine the limits of machinery, ID hazards and estimate risk

involved

Risk evaluation – allows judgment to be made on the safety ofmachinery

Risk Assessment

Mechanical hazards:

Contact or entanglement with the machinery

Trapping between machine and any material or fixed

structures

Contact or entanglement with any material in motion

Hazard Identification - Mechanical

Hazards



Mechanical hazards:

Being struck by ejected parts of the machinery

Being struck by material ejected from the machinery

Hazard Identification - MechanicalHazards

Possible machinery-related injuries:

Crushed hands and arms

Severed fingers

Blindness

Death

Machinery-Related Injuries



Non-Mechanical hazards:

Handling and lifting

Access

Slips, trips and falls

Falling and moving objects

Obstructions and projections

Electricity

Chemicals

Noise and vibration

Suffocation

Ionizing and non-ionizing radiation Fire and explosion

Hazard Identification – Non-MechanicalHazards

Technical and human possibilities to avoid or limit theharm

By whom the machinery is operated – skilled vs. unskilled,manned vs. unmanned

The speed of appearance of the hazardous event – sudden, slow or fast

Any awareness of risk – general information, indicating

devices

Human possibility of avoidance or limiting harm in terms of

reflex, agility or possibility of escape By practical experience and knowledge

Risk Estimation



Step 3: Information for use• At the machine (warning

signs)• In the instruction handbook

Step 2: Safeguarding andcomplementary protectivemeasures

Step 1: Inherently safe designmeasures

Risk Assessment

• Organization – provide SWP,supervision, PTW systems

• Provision and use of additionalsafeguards• Use of PPE• Training• Etc

DesignerInputUser

InputProtective measures taken by the User

Protective measures taken by the Designer

RISK

RISK

Residual risk

afterprotective

measureshave been

taken by

designer

Residual riskafter all

protective

measures have

been taken

Risk Reduction Process

Hazard management – user check

General:

E.g. reduce speed / distance of movement

Reduce force, torque and inertia

Reduce maximum clearance between relatively moving

parts – avoid body part from accidentally entering the gap

Hazard Reduction

Methods Controls

Position & identification of start, stop & E. stop controls

Warning signals

Hazard Management



Indicators – to warn of a hazardous situation

Braking Systems – bring hazardous moving parts to rest as quicklyas possible

Safety catches, overrun and fall-back protection devicesCounterweights and similar devices

Rotating shafts, spindles and couplingsFeeding and take-off devicesHydraulic and pneumatic systems

Lifting, handling and transportLubrication

StabilityLighting

Hygiene

Safety colors and symbolsOperating stations – platforms and steps

Hazard Reduction Methods

Major types of machine guarding:

1. Fixed Guard – kept closed and in place

2. Interlocking Guard – movable or has a

movable part, whose movement isinterconnected with the power orcontrol system of the machine

3. Push-away Guard – is moved into

position by the machine. Also known as“sweep away guard”

Types of Machine Guards



Adjustable Guard – fixed or movable guard which is adjustable asa whole. Remains fixed during particular operation

Self-Adjusting Guard – fixed or movable guard which either inwhole or in part adjusts itself to accommodate the passage ofmaterial

False table – carries material to the operating point of machine

Types of Machine Guards

Machine Safeguarding Basics



In order to protect workers against mechanical hazards,safeguards must meet the minimum generalrequirements listed below:

Prevent Contact

Secure

Protect from Falling Objects

Create No New Hazard

Create No Interference

Allow Safe Lubrication

Basic Machine SafeguardingRequirements

Material:

Ability to withstand the force of ejection

Weight and size in relation to the need to be removed andreplaced for routine maintenance

Compatibility with the material being processed

Ability to maintain its physical and mechanical properties

(contact with potential contaminants)

Suitable material if viewing of machine operation is required

through the guard

Should not degrade, become brittle and fracture, deform,

emit toxic and flammable fumes

Guard Construction



Trip device

A device which causes working machinery to stop or assume

an otherwise safe condition

To prevent injury when a person approaches the danger zone

Mechanical trip device

Electro-sensitive protective equipment

Pressure-sensitive mats and floors

Two-hand control device

Trip Devices

Mechanical Restraint Device

A device that applies mechanical restraint to a

hazardous part of machinery which has been set inmotion due to failure of the machinery controls or otherparts of the machinery

To prevent a hazardous situation

Down-stroking platens

Mechanical Restraint Device



Planning Control power source

Uninterrupted power supply etc

Layout of machinery and plant

Moving parts

Services

Lighting

Access for maintenance

LOTO procedures

Cables conduit and services pipes

Installation Considerations

Operational maintenance of safeguards

Regular inspections

Trained and experienced personnel

Check on normal machinery control and operational

functions

Implementation of safe systems of work – access todanger zone

Waste and spillage removal

Removal of swarf, trade waste or spilled materials

Maintenance



For working machinery

For isolation and dissipation Security at interlocking access gates

Supervisory control

Permit-to-control systems

Information and training

Instruction placards and warning labels

Installation, operation and maintenance

Target audience:

Machinery operators

Plant engineers and maintenance staff

Safe Work Practices

Examples for discussion
















Protectives Measures



1. Definitions

2. Principles of risk assessment and reduction

3. Hazard management

4. Safeguards and safety devices

5. Installation considerations

6. Maintenance

7. Safe Work Practices

Summary of SS 537

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