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Machine Machine GuardingGuarding

Presented by:TITO L. BRIZUELA, JR Safety Officer/Quality Assurance Engineer National Power Corporation Tiwi Geothermal Power Plant

Course OverviewCourse Overview Hazard IdentificationHazard Identification Risk AssessmentRisk Assessment Types of GuardsTypes of Guards Guard DesignsGuard Designs Other ControlsOther Controls

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Machinery is a major Machinery is a major hazard at work..hazard at work..

8 out of 10 workplace fatalities 8 out of 10 workplace fatalities and 1 in 4 workplace injuries and 1 in 4 workplace injuries involve mechanical involve mechanical equipment.equipment.

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Management Management ResponsibilityResponsibility Machinery must be reasonably well Machinery must be reasonably well

guarded.guarded. Built-In guards are always preferable to Built-In guards are always preferable to

built-on guards.built-on guards. Temporary, makeshift and flimsy guards Temporary, makeshift and flimsy guards

imply that management is not sincere in imply that management is not sincere in its efforts to protect the employee.its efforts to protect the employee.

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Where there is a risk of exposure to Where there is a risk of exposure to dangerous parts during:dangerous parts during: operationoperation examinationexamination lubricationlubrication adjustmentadjustment maintenance,maintenance,

that that riskrisk must be must be eliminatedeliminated,, or, or, where it cannot be eliminated, where it cannot be eliminated, minimizedminimized..M

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HAZARD HAZARD IDENTIFICATIOIDENTIFICATIO

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Hazard IdentificationHazard Identification a a HazardHazard is something which could is something which could

cause injury. Unsafe workplace cause injury. Unsafe workplace conditions or practices (dangers) that conditions or practices (dangers) that could cause injuries or illnesses (harm) could cause injuries or illnesses (harm) to employees.to employees.

a a RiskRisk is the likelihood of the hazard is the likelihood of the hazard causing an injury, and the likely severity causing an injury, and the likely severity of an injuryof an injury

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What is a hazard?

Hazard/RiskHazard/RiskFor example, a piece of plant orFor example, a piece of plant ormachinery may be a potential hazard;machinery may be a potential hazard;however, it may not necessarily pose ahowever, it may not necessarily pose arisk unless it is incorrectly guarded orrisk unless it is incorrectly guarded orthe operator is inadequately trainedthe operator is inadequately trained..

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what parts of a machine do what parts of a machine do you look at to find the you look at to find the

Danger AreasDanger Areas??

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spot the spot the hazardshazards

Danger AreasDanger AreasTypically, the following 2 areas on machinery Typically, the following 2 areas on machinery are dangerous, and can be a risk to anyone are dangerous, and can be a risk to anyone near the machine:near the machine:

1. 1. Parts which move or transmit Parts which move or transmit powerpower2. 2. Parts that do the workParts that do the work

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belts & pulleysbelts & pulleys• flywheels & gear wheels flywheels & gear wheels • shafts & spindlesshafts & spindles• slides & camsslides & cams• chain & sprocket gears chain & sprocket gears

Danger AreasDanger Areas1. 1. Parts which move or transmit powerParts which move or transmit power

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• tools & diestools & dies• blades blades • cutterscutters• sawssaws• drills and chucksdrills and chucks• rollersrollers

Danger AreasDanger Areas2. 2. Parts that do the Parts that do the workwork

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To identify dangerous To identify dangerous machine parts look for:machine parts look for:

• shear pointsshear points• drawing-in pointsdrawing-in points• impact and crushing impact and crushing

areasareas• entanglement areasentanglement areas• stabbing pointsstabbing points• cutting areascutting areas• abrasion areasabrasion areas• flying particlesflying particles• protrusionsprotrusions

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spot the spot the hazardshazards

Shear

Nip

Ent

angle

Stab

Draw

in

Crush

Stab

Protrusion

• contact or entanglement with contact or entanglement with machinerymachinery

• trapping between machine and trapping between machine and material or a fixed structurematerial or a fixed structure

• contact with material in motioncontact with material in motion• being struck by material ejected from being struck by material ejected from

a machinea machine• release of potential energyrelease of potential energy

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Machine hazards Machine hazards controlled by guarding controlled by guarding include:include:

RISK ASSESSMENTRISK ASSESSMENT

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Assess the RisksAssess the RisksOnce you have identified the danger Once you have identified the danger areas (hazards), you should areas (hazards), you should assessassess the the risk (how likely it is to cause injury, and risk (how likely it is to cause injury, and how severe the injury could be)how severe the injury could be)

...and ...and control control these risks by guarding or these risks by guarding or in some other effective wayin some other effective way

Complete the following chart to determine Complete the following chart to determine the level of risk for each hazard identifiedthe level of risk for each hazard identified MAJ

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The Risk Priority ChartThe Risk Priority Chart

• If you score a 1 or 2, do something If you score a 1 or 2, do something NOW.NOW.• If you score a 3 or 4, plan to do something soon.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 If you score a 5 or 6, plan to review the risk in the

future.future.

1. Elimination1. Elimination2. Substitution2. Substitution

3. Engineering Controls3. Engineering Controls4. Administrative controls4. Administrative controls

5. Personal protective equipment5. Personal protective equipment

Control the RiskControl the RiskSelect Select Risk ControlRisk Control measures from the highest measures from the highest possible level of the following possible level of the following HierarchyHierarchy::

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EliminationElimination‘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.

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SubstitutionSubstitution‘Substitution’ involves replacing a hazardous piece of machinery or a work process with a non-hazardous one. Forexample:➣ 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

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EngineeringEngineeringIf 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

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AdministrationWhere ‘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)

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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

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PPEPersonal 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

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Make sure machine Make sure machine guards are in place!!guards are in place!!

• all guards should be correctly and all guards should be correctly and securely fitted securely fitted BEFOREBEFORE operating a operating a machinemachine

• machine guarding is vital to every machine guarding is vital to every workplace using machineryworkplace using machinery

• guards need not be complicated nor guards need not be complicated nor interfere with productivityinterfere with productivity

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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?

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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 each employee to use proper lifting procedures. Personal Protective Equipment. Can't use the body belt... it doesn't protect anyone. I don't know what you could use. Do you?

TYPES OF TYPES OF GUARDSGUARDS

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Selecting a GuardSelecting a GuardThere are a number of different There are a number of different typestypes of guards, all suited to of guards, all suited to particular purposes. particular purposes.

You must consider which type of You must consider which type of guard is best suited for guard is best suited for your your needsneeds..

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Fixed GuardsFixed Guards• no moving parts no moving parts • protect only when fixed in positionprotect only when fixed in position• should be easy to remove and replaceshould be easy to remove and replace• are only opened or removed with a are only opened or removed with a tooltool• simple, low maintenance, often the simple, low maintenance, often the

cheapest form of guardingcheapest form of guarding• may interfere with production/maintenancemay interfere with production/maintenance

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Pedestal Grinder with Fixed and Adjustable Guards

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Interlock GuardsInterlock Guards have moveable parts that are have moveable parts that are

interconnected with the control system interconnected with the control system usually electrical, mechanical, hydraulic usually electrical, mechanical, hydraulic

or pneumatic interconnectionsor pneumatic interconnections machinery will not operate unless guard machinery will not operate unless guard

is closed is closed less likely to slow productionless likely to slow production• generally more expensive and require generally more expensive and require

more checking and maintenancemore checking and maintenance

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Interlocked Guard on Dough Divider

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Automatic GuardsAutomatic Guards• automatically moves into position automatically moves into position

as the machine, or cycle, is startedas the machine, or cycle, is started• guard movement/velocity may guard movement/velocity may

create a hazardcreate a hazard• only suitable for slower machine only suitable for slower machine

cyclescycles push away guardspush away guards self-adjusting guards, etcself-adjusting guards, etc

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Self Adjusting Guard - Radial Arm Saw

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Push Away Guard

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Instrument Air Compressor with removed guard

• permanentpermanent• simplesimple

Distance GuardsDistance GuardsA A fixed guardfixed guard that prevents that prevents access to a dangerous area access to a dangerous area through a through a barrierbarrier or or fencefence

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Fixed and Interlocked Barrier Fence Guard

Presence-sensing DevicesPresence-sensing DevicesDetect the presence of a person, or part Detect the presence of a person, or part of a person, in a defined area and of a person, in a defined area and prevents the dangerous parts of prevents the dangerous parts of machinery moving while they are in that machinery moving while they are in that areaarea

• photo-electric light curtainsphoto-electric light curtains• infra-red scannersinfra-red scanners• pressure matspressure mats

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Presence Sensing Laser Scanner

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Light

Curtain

BarrierFence

Combination of Guards - Manual Loading Robots

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GUARD DESIGNGUARD DESIGN

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Guard DesignGuard Design• the primary function of a guard is to the primary function of a guard is to

provide a physical barrierprovide a physical barrier which which prevents access to dangerous parts of a prevents access to dangerous parts of a machinemachine

• poorly designed or inappropriate guarding poorly designed or inappropriate guarding has often contributed to machinery injurieshas often contributed to machinery injuries

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• design for design for easy removaleasy removal andand replacementreplacement - - makes tasks such as cleaning, machine makes tasks such as cleaning, machine adjustment or belt changes easier - adjustment or belt changes easier - particularly if this needs to be done regularlyparticularly if this needs to be done regularly

• guards can only be removed with the aid of a guards can only be removed with the aid of a tooltool

• hinged guards must be hinged guards must be interlockedinterlocked• guard material must be of a good qualityguard material must be of a good quality• good design will aid dust and noise reductiongood design will aid dust and noise reduction

Guard DesignGuard DesignM

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Guard ErgonomicsGuard Ergonomics

• Arm reach Arm reach 850mm - under arm to fingertip850mm - under arm to fingertip• Elbow reach Elbow reach 550mm - inside elbow to finger tip550mm - inside elbow to finger tip• Wrist reachWrist reach 230mm - wrist to tip of middle finger230mm - wrist to tip of middle finger• Vertical reachVertical reach 2500mm - floor to danger point2500mm - floor to danger point• Finger reach Finger reach 130mm130mm

Reach MeasurementsReach Measurements - design and position - design and position guards to restrict access to danger points as guards to restrict access to danger points as follows:follows:

* distances include an * distances include an allowance for clearance from allowance for clearance from danger pointsdanger points

ReachReach Minimum Distance Minimum Distance AssumedAssumed

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Guard PlacementGuard Placement

- 15mm- 15mm- 120mm- 120mm- 200mm- 200mm- - 1000mm1000mm

* distance from underside of guard to the * distance from underside of guard to the floor shall not exceed 250mmfloor shall not exceed 250mm

Size of mesh or Size of mesh or other opening other opening in guardin guard

• less than 9mmless than 9mm• 9 to 25mm9 to 25mm• 25 to 40 mm25 to 40 mm• greater than greater than

40mm40mm

Minimum distance Minimum distance between guard between guard and danger pointand danger point

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Use of Mesh for Guards

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If the distance from moving part to guard is less than 100 mm, wire mesh opening should not exceed 12.7 mm (1/5 in.)

For distances more than 100 mm (4 in.) and less than 380 mm (15 in.)., opening should not exceed 51 mm (2 in.)

GUARDS FOR COMMON GUARDS FOR COMMON MACHINE TYPESMACHINE TYPES

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cut-off sawscut-off saws

milling machinesmilling machines

friction cuttingfriction cutting

boring equipmentboring equipment

Exposed Rotational Exposed Rotational CuttingCutting

FixedFixed and and moving guardsmoving guards should be should be fitted where appropriatefitted where appropriate

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Bridge Guard - Wood Planer MAJ

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Top Guard - Rip Saw MAJ

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Rotating Shafts and Rotating Shafts and RollersRollers

Fixed guards are preferred for rotating shafts and rollers, such as:

* must protect against loose clothing and * must protect against loose clothing and long hair becoming caught in rotating long hair becoming caught in rotating shaftsshafts

• couplings• spindles• fan-shafts• ironing rollers

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RollersRollers

Roller Roller HazardHazard

(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 BetweenCaught in Between

Roller Roller GuardingGuarding

Conveyors (Bulk Handling)Conveyors (Bulk Handling)Main TypesMain Types• belt conveyorsbelt conveyors• screw conveyorsscrew conveyors• bucket conveyorsbucket conveyors

……all require guarding, usually withall require guarding, usually with fixed guardsfixed guards

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On On belt conveyorsbelt conveyors the most important the most important danger points are the nip points.danger points are the nip points.

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Power PressesPower PressesTwo Categories:Two Categories:

power stamping pressespower stamping presses brake pressesbrake presses

* guards should prevent access to the * guards should prevent access to the trapping area at all times when the trapping area at all times when the press is press is strokingstroking

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Power Stamping PressPower Stamping Press

• fixed guardfixed guard• interlockedinterlocked• presence sensing devicespresence sensing devices• two-handed controlstwo-handed controls• usually a usually a combinationcombination of these is appropriateof these is appropriate

Guard type will depend upon the job and Guard type will depend upon the job and the associated hazardthe associated hazard

* it is mandatory that * it is mandatory that regularregular operational operational checks and maintenance is conducted and checks and maintenance is conducted and recordedrecorded

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Power Stamping Press GuardingMAJ

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Brake PressBrake Press• generally generally presence sensing presence sensing

devicesdevices (eg light curtains) are (eg light curtains) are appropriateappropriate

• ““dead man” type foot pedal dead man” type foot pedal actuator for each operator actuator for each operator

• guard front guard front and rearand rear

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Brake Press Guarding System

OTHER CONTROLSOTHER CONTROLS

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Other SafeguardsOther Safeguards physical guarding is not the only safety physical guarding is not the only safety

aspect of Machine Guardingaspect of Machine Guarding

other other safeguardssafeguards are required to maintain a are required to maintain a safe system of worksafe system of work

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all machinery should be fitted with a means all machinery should be fitted with a means of isolation from all energy sources (except of isolation from all energy sources (except those required for safety systems) those required for safety systems)

isolators should be clearly identified and be isolators should be clearly identified and be capable of being locked if reconnection could capable of being locked if reconnection could place persons at risk (during maintenance, place persons at risk (during maintenance, repairs, etc)repairs, etc)

Isolation ProceduresIsolation ProceduresM

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Lock Out / Tag Out Isolation System

An appropriate An appropriate isolation method is a isolation method is a lock-out/ tag-out lock-out/ tag-out systemsystem,, in which in which one or more one or more padlocks are fitted padlocks are fitted to the isolation to the isolation switch, as well as switch, as well as danger tags with the danger tags with the exposed persons' exposed persons' names on them.names on them.

Isolation: Lock-out/ tag-outIsolation: Lock-out/ tag-outM

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Emergency Stop ControlsEmergency Stop Controls• shall be shall be prominentprominent and readily and readily accessibleaccessible from from

all operator positionsall operator positions• coloured coloured redred• suitably markedsuitably marked

- Emergency Stop Buttons shall be “mushroom head” Emergency Stop Buttons shall be “mushroom head” latch-in or lock-in manual reset typelatch-in or lock-in manual reset type

- lanyards, trip wires or similar devices are acceptablelanyards, trip wires or similar devices are acceptable

• require a require a manual resetmanual reset before restarting before restarting• not to be used for normal stoppingnot to be used for normal stopping• not to be relied upon for isolationnot to be relied upon for isolation• NOT an alternative to guardingNOT an alternative to guarding

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Access ProvisionsAccess Provisions machinery machinery designdesign should allow routine should allow routine

adjustment, lubrication and maintenance adjustment, lubrication and maintenance without removing guards or extensive without removing guards or extensive dismantling of componentsdismantling of components

lubrication and routine maintenance lubrication and routine maintenance facilities should be incorporated facilities should be incorporated outsideoutside the danger area wherever practicalthe danger area wherever practical

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TrainingTraining• in safe working procedures, guarding and hazards in safe working procedures, guarding and hazards

of the machine they operateof the machine they operate• training records shall be kepttraining records shall be kept

AdministrationAdministration Safe Operating ProceduresSafe Operating Procedures shut down proceduresshut down procedures maintenance schedules maintenance schedules

and recordsand records

Personal Protective EquipmentPersonal Protective Equipment• used used if not possibleif not possible to completely control the to completely control the

hazardhazard• check fit, comfort, maintenance, correct use & check fit, comfort, maintenance, correct use &

trainingtraining

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ERGONOMIC CONSIDERATIONSERGONOMIC CONSIDERATIONSThe following illustrations and tables may The following illustrations and tables may

help you assess what sort of guarding is help you assess what sort of guarding is required and where it should be located (in required and where it should be located (in order to keep a danger point on a machine order to keep a danger point on a machine safely out of reach).safely out of reach).

Where doubt exists in relation to the Where doubt exists in relation to the distances shown, measurements should distances shown, measurements should be taken of the actual work place to be taken of the actual work place to ensure danger points are beyond reach.ensure danger points are beyond reach.

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According to Kent’s Mechanical Engineers HandbookAccording to Kent’s Mechanical Engineers Handbook A GOOD GUARDA GOOD GUARD

• Provides positive protection and prevents all access to danger Provides positive protection and prevents all access to danger zone during operation.zone during operation.

• Does not interfere with the operation of the machine, permits Does not interfere with the operation of the machine, permits convenient and safe lubrication, adjustment and repairs.convenient and safe lubrication, adjustment and repairs.

• Is strong and durable, fire and corrosion resistantIs strong and durable, fire and corrosion resistant

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A GOOD GUARD A GOOD GUARD

• Does not have splinters or sharp edges and projections which may cause Does not have splinters or sharp edges and projections which may cause injuryinjury

• Is designed to prevent tampering and yet permit authorized removal and Is designed to prevent tampering and yet permit authorized removal and adjustmentadjustment

• Does not interfere with the operator or cause eye strain or other Does not interfere with the operator or cause eye strain or other discomfort.discomfort.

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Legislative FrameworkLegislative FrameworkM

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Occupational Safety and Health Occupational Safety and Health Standards as amendedStandards as amended describes how describes how to provide health and safety in workplaces to provide health and safety in workplaces and is a law that must be followedand is a law that must be followed

Rule 1200 of the same standardRule 1200 of the same standard set out set out the general principles, providing practical the general principles, providing practical steps to be followed for machine guardingsteps to be followed for machine guarding

Approved Codes of PracticeApproved Codes of Practice e.g. American e.g. American Standards Association and National Safety Standards Association and National Safety Council provide practical guidance to meet Council provide practical guidance to meet the legal requirements of the Act and the legal requirements of the Act and Regulations and must be followed unless an Regulations and must be followed unless an equal or better solutions can be appliedequal or better solutions can be applied

Without Without Appropriate Appropriate Guard this will happenGuard this will happen

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Safety & Health PayoffsSafety & Health Payoffs

THANK YOUTHANK YOU