ࡱ>   ubjbjΚΚ yks$P, $P ?$!$!4X!X!X!X!X!X!>>>>>>>,Ĵ2'?!!!!!'?#!!d#X!>d#d#51 >raG "ZM><>?0?><Dd#Dx>d#> X!X!X!'?'?d#X!X!X!?DX!X!X!X!X!X!X!X!X! ~:   * INTERPRETATION - "Department" means College/School/Department/Centre/Unit as relevant. 18.33.1 INTRODUCTION Workshop machinery includes all types of machines, from manual, automatic and CNC (Computer Controlled) machines, which are used for a variety of tasks. These would include cutting, drilling, milling, grinding, rotating, shearing, pressing, punching, sawing and shaping of wood, metal, plastic or stone or other materials. Due to the wide variety of working machines in the ҹ޸þ, Heads of Departments must bear in mind the relevant legal constraints as regards training, instruction, supervision, competency, minimum age of users, protective equipment etc. Consider in particular current Health & Safety legislation for Regulations pertaining to , Dangerous Machines (Training and Supervision of Persons) , Operation of Unfenced Machinery , Abrasive Wheels Woodworking Machinery etc. Persons under the age of 18 years should not operate machinery unless they have received sufficient training and are supervised by an experienced person. 18.33.2 HAZARDS The main hazards associated with the use of all machinery are accidents and ill health resulting in: Hand & Limb injuriesFatalitiesDislocationsManual Handling injuriesElectric ShockAbrasionsFriction burns or CutsDeafness from noise levelsAmputationsEye injuriesEntanglementVibration effectsSkin irritation or dermatitisBronchitis or asthma Ejection of particlesImpact injuries Most accidents at all types of machines happen to users during normal operations when either: Loading or unloading components Removing swarf Taking measurements or making adjustments On manually operated machines like presses, drills, lathes, metal cutting saws, guillotines. mills, grinders the most dangerous machine movements of tools are rotation, cutting, shearing, sawing or pressing. These have resulted in a high incidence of hand injuries, many of which are severe. With automatic or CNC machines the greater number of accidents occur at clamps, tables, chucks and other work handling equipment. In addition, a great number of accidents occur to untrained operators, setters, electricians, maintenance personnel when they are setting up, fault- finding or making repairs, with all types of machinery. 18.33.3 RISKS The risks associated with the aforementioned hazards are to be assessed by the Department (using the appropriate technical input where necessary). These assessments shall be carried out using: Check lists provided (where applicable) and Departmental Hazard Identification/Risk Assessment Work Sheets contained in Document No.3 i.e. Departmental Hazard Risk Assessment (D.H.R.A.). ARRANGEMENTS AND CONTROLS REQUIRED FOR WORKSHOPS: These hazards and risks will be minimised by the following arrangements and controls in each sub-section: PRINCIPLES OF SAFEGUARDING MACHINERY ALL MACHINERY WOODWORKING ABRASIVE WHEELS DRILLING (AND REAMING) MACHINES MILLING AND MACHINING CENTRE WORK PRESSING MACHINES (Mechanical, Hydraulic and Pneumatic) TURNING MACHINES METAL CUTTING CIRCULAR SAWS GUILLOTINES WELDING AND FLAME CUTTING (also Brazing and Soldering) BENDING USING 3 ROLL BENDING MACHINES HAND TOOLS 18.33.4.1 PRINCIPLES OF SAFEGUARDING MACHINERY The basic principle of safeguarding machinery is that unless a danger point is safe by virtue of its position, the machinery must be fitted with an appropriate safeguard. This specific safeguard should eliminate or reduce danger before access to the danger point is possible. To apply the above principle, the following points should be taken into account: Dangerous parts should ideally be eliminated or effectively enclosed at the machine's design stage. If they cannot be eliminated, then suitable safeguards (e.g. guards, safety features and emergency controls) should be incorporated as part of the design. (This is a requirement under EU law). Provision should be made to facilitate the fitting of alternative types of safeguards on machinery if it is known that the work pieces to be accommodated will vary in size and shape. Where an openable/re-moveable guard, cover etc. is used as a safeguard, it must be interlocked with the drive mechanism of the dangerous parts. NOTE: The latter would not apply to adjustable guards on machines such as band saws or crown guards to a woodworking circular saw). Maintenance operations set up/cleaning operations should therefore prevent the machine from operating. Lubrication points and routine maintenance facilities must be incorporated outside the danger area wherever practicable. Provision should be made for the machine to be turned off, energy controls locked off and tested to ensure it is at zero energy, before guards are removed/maintenance work is undertaken. Suitable supplementary lighting should be provided at operating points. Any lighting fitting which is portable and easily adjustable should preferably be supplied from a low voltage supply. Every mechanism and control forming part of the safeguard should as far as practicable be of fail-safe design. All automatic and CNC machines must use fixed or interlocking safety devices to ensure all dangerous movements of the machine/tools are guarded. Work zone enclosures should be used where the speed and power of the machine may lead to risk of injury. All safeguards on all machinery should be of sound design and adequate strength and should conform to latest Codes of Practice for the Safety of Machinery. Guards may be made of metal, timber, laminated or toughened glass suitable plastics or a combination of these as may be appropriate to the conditions. The shatter resistant properties of materials may need to be considered where impact or flying materials is a hazard. Whatever safeguard is selected, it should not itself present a hazard such as trapping or shear points, splinters, rough or sharp edges or other sources likely to cause injury. Safe means of removing swarf (such as hook or rake) should be available for use when the machine has turned off. Guards should also be used in parallel with local extraction ventilation (LEV), to enclose and control hazardous substances. Where noise is excessive the guards may serve as noise control enclosures by lining them with sound absorbent materials. In running nips at rollers/pulleys and the ends of rotating rollers or spindles require to be guarded. On/Off controls and an emergency stop button should be provided at each machine at easily assessable locations (convenient to the operator). 18.33.4.2 ALL MACHINERY Every operator should be trained competently and know the main hazards of the machines prior to use, they should also know: How to start operate and stop the machine safely How the safeguards and other controls work What to wear e.g. appropriate PPE and what not to wear e.g. loose garments, jewellery, ties, long hair etc. How to load and unload components safely and safe manual handling practices The dangers of metal working fluids from skin contact and breathing aerosols of fluids or fumes How to remove swarf, debris, chippings and adjust machine coolant flow Good housekeeping procedures around dangerous machines All maintenance and setting personnel should be trained and know the main hazards of machines; they should also know: How to use the permit to work system (especially for work on complex or hazardous plant) Know where the power isolation switch is located Ensure power is switched off and securely isolated (using their own snap lock and tag) before inspection, cleaning, maintenance or repairs are carried out Ensure other energy sources are isolated (as above) and the energy source dissipated 18.33.4.2 ALL MACHINERY (contd.) Ensure any fluid lines containing harmful chemicals are isolated (as above) and any residue drained down How to display warning signs properly How the safeguards and other controls work What to wear e.g. appropriate PPE and what not to wear e.g. loose garments, jewellery, ties, long hair etc. The dangers of metal working fluids from skin contact or breathing aerosols How to remove swarf, debris, chippings and adjust machine coolant flow Safe manual handling practices during maintenance Good housekeeping after maintenance or repairs around dangerous machines GENERAL Machinery should only be used with written Departmental authorisation and when the user is confident that he/she has received and understood all the relevant instructions. Non-workshop personnel should not be authorised to use routers, band saws, horizontal milling machines, press brakes, power presses, planing machines, circular saws or other hazardous machinery. With all dangerous machinery and equipment, ensure it is switched off and left in safe condition after work is finished. Users of machinery should not allow themselves to be distracted by others and should concentrate on the task in hand. Likewise, never speak or distract someone working dangerous machinery. 18.33.4.3 WOODWORKING (In addition to the relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Many serious accidents have occurred e.g. fingers or hand amputated from contact with running blades when feeding, adjusting or removing work pieces and when cleaning machines. Other ill health concerns are noise (blade against the work piece), inhalation of harmful wood dusts and unsafe manual handling practices. Woodworking machines must not be operated without the appropriate safe guards in place. Written codes of good working practice adopted from the current Woodworking Machinery Regulations should be implemented. Circular Saws - The blade of a bench-mounted circular saw must be safeguarded in three ways:- the portion of the saw blade below the bench must be enclosed; a riving knife must be provided behind the saw blade which should be adjusted to be within 13mm of the saw blade at bench level; a top guard for the crown and front of the saw must be provided. A variety of the latter are available and the design most appropriate for the work should be chosen. Bandsaws On modern machines, guards are usually to a high standard and the whole blade except for the operative portion is completely enclosed. The length of exposed blade varies according to the thickness of the wood and is determined by setting the top guide. The length of the blade between the top guide and the top pulley will vary in consequence and to protect this portion a guard of U-section metal is fixed to the guide bracket so that it is automatically adjusted with the guide. It should be long enough to overlap the guard for the top pulley when the top guide is in its lowest position. Planing Machines The cutter block must be provided with a bridge guard set centrally over the cutter block and constructed so that it is easily adjustable both in a vertical and a horizontal direction. A rigid sectionalised guard is best for most machines. The guard must be the same length as the cutter block and wide enough to overlap the edges of the tables. A number of spring loaded designs are also commonly found on planing machines e.g. the boomerang guard. Attention is drawn to HSE Guidance Note PM2, entitled "Guards for Planing Machines" available from HMSO or from the ҹ޸þ Safety Office. Cutters, tools and saws should be maintained regularly to ensure they are sharp and running at correct speed. Push sticks must also be used in addition to guards. Any problems with safeguards should be discussed with the Department Safety Officer. Waste, dusts, or chippings should not be allowed to accumulate around machines to reduce the risk of fire. 18.33.4.4 ABRASIVE WHEELS (In addition to the relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Main causes of injuries are as a result of the wheel bursting and by contact of the hand with the rotating wheel. Cutting and crushing injuries from entrapment between wheel and work rest. Fires and explosions arising from poor control of dusts containing aluminium magnesium or similar metals. Other ill health concerns were from noise, manual-handling practices, vibration conditions from hand held grinding machines or from inhaling harmful dust/fume generated. The abrasive wheel must be correctly mounted and checked by a trained and competent person at least to the standard required in the current Abrasive Wheels Regulations. Every abrasive wheel must be provided with a strong metal guard, with reinforced viewing area, which encloses the whole of the wheel except for the operative portion. Guard of sufficient strength to contain fragments of broken wheel Correct selection of wheel and machine for the task. Run new wheels free for about a minute prior to use. Do not grind on the sides of straight sided wheels for off side grinding Lubricate spindles regularly To reduce the risk of contact with the wheel, the rest for supporting the work piece must be properly secured and adjusted as close as possible to the wheel Never stop the wheels by applying pressure to the wheel periphery or face Use wheel dressers or other means to minimise risk of vibration white finger Easily accessible and operated on/off switch Provide LEV for manually operated surface grinding machines IT IS ESSENTIAL THAT A WHEEL IS NEVER OPERATED AT A PERIPHERAL SPEED IN EXCESS OF THAT MAXIMUM PERMISSIBLE SPEED SPECIFIED BY THE MANUFACTURER. (rpm of spindle to be clearly marked). 18.33.4.5 DRILLING (AND REAMING) MACHINES (In addition to the relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Many serious injuries have resulted with drilling machines, either from the operator becoming entangled in the spindle or chuck by his hair, gloves, clothes etc. or by violent spinning of the work piece. Some injuries at large vertical drills or radial arm drills have been fatal. All these accidents can be prevented The main precaution involved is the safeguarding of the chuck and drill bit together with adequate arrangements for the secure clamping of the work piece. The types of safeguards available fall into four categories: Adjustable guard attached to a fixed part of the machine - This type of guard is a fixture but is adjustable to take account of different lengths of drill bits and heights of work piece. Collapsible or "swing-away" guards. Combined guard and jig (this type is used primarily during "production" work). Tripping devices involve the injection of a powerful DC current into the motor windings which exerts a powerful braking torque rapidly bringing the motor to rest. (More effective for radial arm and other heavy drilling machines). These devices are literally life savers and must be considered for larger drills. The position of the vertical trip not more than 75mm from the tool and positioned within the first 90o of rotation from the operators position. For small CNC drilling machines sliding interlocking guards to prevent dangerous movements when guards are open Discharge slide to prevent access to dangerous parts of machine Ensure personnel are instructed in the safe use of drilling machines. This should cover the guarding of spindles and attachments and tripping services for heavy vertical and radial drilling machines. Never leave chuck keys in chucks. Always wear eye protection but not gloves unless complete enclosure of rotating chucks, spindles and attached rotating parts is provided MILLING AND MACHINING CENTRE WORK (In addition to relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Many serious accidents have occurred from either entanglement or contact with rotating cutters when loading or unloading components, removing debris, measuring or adjusting coolant flow. Other ill health concerns were from noise, manual handling practices or metal fluids. The key safety measures for Vertical Milling machines are: Fixed or interlocking moveable guards to prevent access to cutters and chip ejection Component securely fixed Protection from fluids LEV for small machining centre PRESSING (Mechanical, Hydraulic and Pneumatic) MACHINES (In addition to relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Many serious accidents have occurred e.g. fingers or hand amputated or crushed between closing tools when loading or unloading components and setting up. Other ill health concerns were from noise impact of tools, air ejection, repetitive manual handling practices. The key safety measures for Mechanical Presses are: Guards also used as noise enclosures Using automatics feed device for loading /unloading components to prevent access between tools The key safety measures for Mechanical Power Presses using interlocking guards are: Ensure that closing gates overlap by at least 10% of total movement before clutch may be operated Use foot pedals with safety shroud Prevent loose or slack movement of connected parts by preventative maintenance Repair distorted bars The key safety measures for Pneumatic hand-fed press using interlocking guards are: Provide suitable fully adjustable seats with good back support and foot rests Stillages should be positioned to minimise upper limb disorders when lifting or lowering components Ensure overlap of guard and table before press will operate Interlock the pneumatic power supply to the press with movement of the guard Use two pneumatic circuits to check and control interlocking functions to prevent tools closing when guards are open The key safety measures for Hydraulic press brake using photoelectric guards are: Ensure that the back and sides of press are guarded and that no-one can stand between the light curtain and machine; or reach under, around or over the light curtain or guards to dangerous parts Ensure that photoelectric light curtain when interrupted brings downward movement to a halt before dangerous parts can be reached When the beam is switched off, to permit metal sheets to be inserted and bent through the light curtain, a safe distance must be allowed between the top tool and the top surface. (See BS EN 294:1992 for safe distance) TURNING MACHINES (In addition to the relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Many serious accidents resulting in amputation of fingers, broken bones and torn ligaments even fatalities have occurred from entanglement on rotating parts, chucks, carriers etc. Others have occurred using hand held emery cloths to smooth and polish components. Other ill health concerns were from noise levels of multi-spindle machines, unsafe manual handling practices and harmful metalworking fluids. The key safety measures for CNC Lathes are: Sliding interlocking guards to prevent access to dangerous movements when guards are open If access to machine movements is necessary when guards are open, safer, slower movements under hold to run control may be allowed when guards are open Local Exhaust extraction to be fitted Never use emery cloths The key safety measures for Manually operated turret lathes are: Fixed guard at rear of machine Chuck guard to in place Feed and lead screws guarded or well away from operator Splash back for swarf and suds METAL CUTTING CIRCULAR SAWS (In addition to the relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Many serious accidents have occurred e.g. fingers or hand amputated from contact with running blade when feeding, adjusting or removing work pieces and when cleaning the machine. Other ill health concerns were from noise of blade against work piece, harmful metalworking fluids and unsafe manual handling. 18.33.4.9 METAL CUTTING CIRCULAR SAWS (Cont.) The key safety measures for Metal Cutting Circular Saws are: Automatic self-adjusting guards to prevent contact with the blade in the raised position or exposure to the blade while cutting. (Only the portion of the blade necessary to cut the object should be exposed). Gravity operated guards may only be used with hold to run controls Where fixed distance or tunnel guards are used, work pieces should be fed and removed through small openings to deny access to blade Ensure the head spring balance (if fitted) is properly adjusted and maintained Reduce noise at source by using damped saw blades, noise absorbent materials on feed table or head enclosure 18.33.4.10 GUILLOTINES (In addition to the relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Most serious accidents have occurred e.g. fingers amputated from when feeding, or removing work pieces near unguarded blades at the front, sides and rear of machines. Other ill health concerns were from noise of scrap fall of work pieces, unsafe manual handling. The key safety measures for guillotines are: Front guard opening small enough to prevent access to clamps or blade Built in lighting and marker to see cutting line Sloping discharge chute to enable work pieces to be retrieved without opening guards Rear interlocking guard Shrouded foot pedal Automatic guillotines should have light beam trip devices between the blade and the operators position and visual devices to indicate that the beams are operating correctly. 18.33.4.11 WELDING AND FLAME CUTTING (including Brazing and Soldering operations) (In addition to the relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Most accidents when welding have resulted from falling cylinders, electric shock from equipment, fires initiated from sparks or hot parts, eye damage due to unprotected eyes. Other health concerns include unsafe handling, uncomfortable postures, and inhalation of welding fumes, IR. & UV radiation exposure, noise from grinding operations and heat discomfort. Similar processes such as brazing and soldering should include fume control measures such as mobile LEV or ventilated workbenches. Exposure to metallic fumes of materials like colophony, used as flux in electronic soldering affects the respiratory system. This has resulted in occupational diseases including fume fever, asthma and respiratory sensitisation. The key safety measures for manual Metal Arc welding are: Ensure that personnel who carry out any welding process e.g. electric arc, oxy-gas, plasma, puddle are fully trained in welding hazards and safety. Store and use welding gas cylinders safely [See Section 18.16.0 Compressed Gas Cylinders] Welding equipment, hoses, compressed gases, connectors, regulators etc. should be kept in good condition. Personal eye protection should be mandatory at all times and should cover protection from radiation generated by the flame or arc. This includes infrared, ultra-violet, intense visible light, x-rays and in some, process radio frequency radiation. Local exhaust ventilation/respiratory protection should also be utilised to ensure protection from metal fumes and gases including oxides of nitrogen, ozone, carbon monoxide and phosgene from residues on degreased metal. (LEV should be provided to fixed welding booths and should consist of a retractable arm). Other PPE includes overalls, apron, gloves and safety boots Ensure insulated electrode holder and insulated box for electrode holder Earthing of work pieces when required (e.g. arc welding) Provision of suitable and accessible fire extinguisher (nearby) Proper cable connections, well-insulated and local isolation switch. A welding set transformer Welding screens to the latest BS EN standard (to prevent arc eye). [Note: This is required where welding is undertaken temporary in construction sites]. The key safety measures for Resistance Welding Machines are: Personal eye protection should be mandatory at all times if an effective screen is not fitted Shrouded foot pedals mandatory Where component has to be supported with one or both hands a sensing guard must be fitted Where component has to be placed or held within the machine fixed and interlocking guards should be used. If this is not practicable, two hand control should be used The key safety measures for Lasers used for Welding and Cutting are: [See also Section 18.27.0 Non Ionising Radiation] Compliance to latest BS EN standard - Safety of laser products recommended instructions Prevention of exposure to fumes with LEV (local exhaust ventilation) Anti-scatter guards located at cutting/welding heads Enclosures, fixed guards and interlocking access doors to contain reflection from high power machines Guards to prevent access to dangerous parts/machine movements Prevention of contact to live electrical parts. (CO2 lasers operate at extremely high voltages, which may remain lethal because of stored energy even after isolation of electrical supplies). Prevention of fire where laser emissions exceed a few watts The key safety measures for brazing and soldering operations are: Appropriate PPE is provided and used. Ensure insulated holders for soldering irons are available. Local exhaust ventilation (LEV) should be in use to prevent exposure to fumes, gases and respiratory sensitizers. Ensure personnel are trained and are aware of hazards. Ensure usage of lead free solders compliant with RoHS Directive 18.33.4.12 BENDING USING 3 ROLL BENDING MACHINES (In addition to the relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Most accidents have occurred e.g. hand drawn into or crushed between counter-rotating rollers when feeding of the workpiece and setting up. Other ill health concerns are unsafe feeding/unloading of work pieces which are too heavy/sharp/awkward. The key safety measures for using 3 Roll Bending machines are: Hold-to-run controls should automatically return to stop on release Emergency stop buttons requiring manual reset after use Foot pedal shrouds Brake system to achieve a safe stopping time Trip devices to be positioned so facilitate rapid activation by any person drawn towards both sides of machine to bring to a stop before serious injury Feed tables and rollers to be used to reduce gripping pieces close to the rollers Do not wear gloves during initial feeding of pieces Keep area clear and clean around machines to prevent slips & trips The in-running nip position between rollers rotating in the opposite direction should be guarded and the gap kept to the absolute minimum (width of material). In most cases, a gap of 3mm should be the maximum. 18.33.4.13 HAND TOOLS (In addition to relevant requirements given in Sections 18.33.4.1 and 18.33.4.2) Many serious injuries have occurred with the use of many common hand tools to limbs and eyes because simple precaution had not been taken and observed or work was rushed. The key safety measures for Hand Tools are: Ensure all hand tools are in good condition before use. Do not use tools with damaged handles or chisels with mushroom heads. Wear suitable eye protection where fragments of stone, metal, glass may be generated Wear suitable hand protection where there is any exposure to sharp or rough materials Portable power tools (see Section 18.32.0). 18.33.5 ARRANGEMENTS AND CONTROLS The details of the Arrangements and Controls in place and those required in the short, medium and long term, shall be set out by the Department in the forms provided in Document No.4 i.e. Departmental Safety Action Plan (D.S.A.P.). These Arrangements and Controls shall be reviewed and updated on a yearly basis. 18.33.6 RESPONSIBILITIES The following personnel are responsible in the Department/Office/Area for ensuring the implementation and ongoing compliance with the aforementioned arrangements and controls. AREA/LOCATIONPERSON RESPONSIBLE1.2.3.4.5.6.   DEPARTMENT SAFETY STATEMENT DOCUMENT NO. 2: Requirements for the Control of Hazards and Risks SECTION 18.33.0 - Engineering & Scientific Workshops Rev.3 PAGE   PAGE 8 of  NUMPAGES 8 AppSc\Doc2\Sect 18.33 DOCUMENT NO. 2: Requirements for the Control of Hazards and Risks SECTION 18.33.0 - Engineering & Scientific Workshops (Cont.) 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