plant safety checklist

PLANT SAFETY CHECKLISTPURPOSETo assist Seventh-day Adventist Church administrators, managers, supervisors and employees, including volunteers, to control risks arising from the use of plant.

WHAT IS PLANT?“Plant” is defined in the National Standard for Plant as “any machinery, equipment (including scaffolding), appliance, implement or tool and any component or fitting thereof or accessory thereto.”

The definition is broad, encompassing a broad range of equipment and items found in the workplace. Plant regulations in Australian jurisdictions are based on the National Standard for Plant. There is some variation between states as to what is specifically covered by the regulations. Persons with responsibility for plant safety should refer to local regulations and guidance material provided by local OHS regulators.

WHAT THIS GUIDE PROVIDES Checklists based on Chapter 5 of the OHS Regulations 2001 (NSW). While compliance with

these requirements should ensure the safety of plant in each jurisdiction, responsibility for compliance in each jurisdiction rests with the employer. Each checklist identifies the specific clause on which it is based, eg “Guarding (cl. 90).

Plant Register.

Plant Risk Management Worksheet.

Risk Management Plan.

WHAT THIS GUIDE DOES NOT COVER Obligations of Designers, Manufactures and Suppliers

Registration of Plant

Obligations of Hirers or Lessors of Plant

Amusement Devices

Plant under Pressure

Earth Moving Machinery

WHAT ARE THE REGULATORY REQUIREMENTS?The regulations require employers to adopt a risk management approach to managing plant. This requires employers to systematically identify all hazards associated with workplace plant and its use, assess the risk, implement necessary controls, and to monitor and review those controls to ensure they remain effective.

EMPLOYEE INVOLVEMENTPlant users are more likely to be aware of hazards associated with specific plant. Effective risk management utilises the knowledge of those involved in the task or activity under assessment. In most cases employers and their employees have the knowledge and skills to successfully manage risk. At times specialist knowledge and expertise will be required.

HIERARCHY OF CONTROLIf elimination of the risk is not reasonably practicable, the following measures (in the order specified) shall be taken to minimise the risk to the lowest level reasonably practicable:

Plant Safety Checklist of 14 July 2004

Substituting the hazard giving rise to the risk with a hazard that gives rise to a lesser risk.

Isolating the hazard from the person put at risk.

Minimising the risk by engineering means.

Minimising the risk by administrative means (eg. by adopting safe work practices or providing appropriate training, instruction or information).

Using personal protective equipment.

A combination of the above measures must be taken to minimise risk to the lowest level reasonably practicable if no single measure is sufficient for that purpose.

GENERAL RISK ASSESSMENTSA general assessment of risk is sufficient if hazards of the same kind occur in different places or circumstances within the workplace so long as that assessment has been applied to each place or circumstance.

USING THIS PACKAGE List all plant in the “Plant Register”. Although the definition of plant is broad, the regulations and

information published by OHS regulators will guide you in the things you should list. Although some equipment, such as scaffolds in Queensland and chainsaws in Victoria do not fall within the scope of their respective plant regulations, hazardous equipment that is not covered by regulation should not be ignored.

Identify all hazards associated with each item of plant. List hazards on the “Plant Risk Management Worksheet”. Checklists included in this package will guide you in relation to specific regulatory requirements. Material published on the internet by regulators, state education authorities and others may also assist hazard identification.

Assess the risk associated with each hazard using the matrix provided in Table 1 or other similar tool provided by a regulatory authority. List the risks, likelihood (L/hood), consequence (Cons) and risk rating on the “Plant Risk Management Worksheet”.

Determine priorities for hazard control based upon the Risk Rating determined from the above step. The lower the numerical value arrived at using the matrix, the higher the priority. Care should be taken when relying on this method alone to determine hazard control priorities. Although an unguarded machine may be regarded as a low priority item, failure to guard the machine is a breach of the regulations that may result in a significant penalty.

List the recommended controls in the “Plant Risk Management Worksheet”. Include both short and long term controls as appropriate. Controls should reflect the priorities of the hierarchy of controls (above).

Transfer relevant information to the “Plant Risk Management Plan”, including the controls agreed upon. Complete the other fields in this document and you have an action plan for managing risks associated with plant.

Complete the outstanding fields in the “Plant Register”. Include a date to review the risk assessment.

Table 1: Risk Assessment Matrix

Likelihood

Consequences

Insignificant

1

Minor

2

Moderate

3

Major

4

Catastrophic

5

A (almost certain) H H E E E


B (likely) M H H E E

C (moderate) L M H E E

D (unlikely) L L M H E

E (rare) L L M H H

Notes:1. Matrix, including the number of categories included, may be varied to suit the requirements of the employing

organisation or workplace.

2. Employing entities may develop specific descriptors for ‘Consequences’ and ‘Likelihood’ to reflect local requirements.

3. The following legend indicates an appropriate response relevant to the level of risk. Each employing entity should clearly define management responsibilities and accountabilities for responding to different levels of risk.

LegendE: extreme risk; immediate action requiredH: high risk; senior management attention neededM: moderate risk; management responsibility must be specifiedL: low risk; manage by routine procedures

Matrix from AS/NZS 4360:1999

SOME RESOURCESThe following list is not exhaustive. Other resources may be more appropriate to your circumstances. Use of these and other resources will help you to make better informed decisions on your plant safety obligations.

Plant Guide 2001 (NSW WorkCover). Provides guidance on complying with plant safety regulations. Available through http://www.workcover.nsw.gov.au/Publications/default.htm. Go > Industry > Plant, scroll down to find publication.

A Guide to Practical Machine Guarding (Workplace Health & Safety, QLD). Available through http://www.whs.qld.gov.au. Go > Publications > Safety guidelines > guides > G >

Machine Guarding, (SA Workplace Services). Provides an overview of the risk assessment process as it applies to guarding. Available through http://www.eric.sa.gov.au/home.jsp. Go > Major Hazards > Machine Guarding >

Plant Hazard Checklist (Vic WorkCover). Provides a range of questions to help assessors identify a range of hazards associated with plant. Includes a range of hazards associated with the need for guarding, plus issues such as ergonomics, electrical hazards, fluids under pressure, etc. Available through http://www.workcover.vic.gov.au/dir090/vwa/home.nsf. Go > Publications > General publications > by category > plant & equipment >

The South Australia Department of Education and Children’s Services provides a range of information that should prove helpful. http://www.decs.sa.gov.au/ohsw/. The publication “Guidelines for the Safe Use of Machinery” has been specifically prepared for the School Design and Technology area. This, along with the Fact Sheets and Standards for Plant available at the same site, should also be helpful in other locations.

The Management of Safety at Woodworking Machines at http://www.safetyline.wa.gov.au/. Go > Essentials > Plant > and scroll down to find the title. Provides specific guidance on the safe set up and use of woodworking machinery.

Making your Forklift Work for You – A Ten Minute Checklist for Managers & Supervisors at http://www.workcover.nsw.gov.au/Publications/default.htm. Go > Safety guides > and scroll down to find the title.


http://www.workcover.nsw.gov.au/Publications/default.htm

http://www.safetyline.wa.gov.au/

http://www.decs.sa.gov.au/ohsw/

http://www.workcover.vic.gov.au/dir090/vwa/home.nsf

http://www.eric.sa.gov.au/home.jsp

http://www.whs.qld.gov.au/

http://www.workcover.nsw.gov.au/Publications/default.htm

Seventh-day Adventist ChurchPlant Risk Assessment Checklist – Guarding (Cl.90)

Site/Location: __________________ Date: ________

Assessor/s: __________________ __________________ __________________

Plant Covered by This Assessment

Name: ____________________________

Serial/Ident No’s: __________________ __________________ ____________________________________ __________________ __________________

(This section continues on the following page)

Requirement Yes

No

T’ferto plantw’sheet

Comment

Where access to a danger point is not required during normal operation, maintenance or cleaning, are all danger points or areas guarded by a permanently fixed physical barrier?Where access to a danger point is required during normal operation, maintenance or cleaning, are all guards designed to be:

an interlocking type physical barrier? or a presence sensing safeguarding system?

Does guarding make by-passing or defeating it, whether deliberately or by accident, as difficult as is reasonably practicable?Is guarding of solid construction and securely mounted so as to resist impact and shock?Is guarding designed so as not to cause a risk in itself?Are guards intended to provide protection from parts of the plant or work pieces that may break, disintegrate or be ejected sufficient to effectively contain the parts, work pieces or fragments?Where it may be necessary to clear any jamming or blockage of moving parts during operation, are employees aware of and trained in the work procedures, devices or tools specified by the designer or other competent person?

Select the GuardThere are a number of different types of guards, all suited to particular purposes. You must consider which type of guard is best suited to your needs. The different types include:

fixed guards – have no moving parts and prevent contact between moving machinery parts and any part of the body. They offer protection only when properly fixed in position. Fixed guards should be easy to remove and replace, but only be able to be opened or removed with a tool.

Interlocking guards – are moveable, with the moving part interconnected with the control system. Interconnections are usually either electrical, mechanical hydraulic or pneumatic. The interlock prevents the machinery from operating unless the guard is closed.

automatic guards – automatically move into position as the machine, or cycle, is started. They are also know as push away guards. These are only suitable on slow machines.

distance guards – prevent access to dangerous areas through a barrier or fence.

trip guards (presence sensing devices) – these stop the machine when a person gets into a position where they are liable to be injured. A photo-electrical curtain is an example of this type of guard.

From A Guide to Practical Machine Guarding, Workplace Health and Safety, QLD

Further Assistance With Guarding


Guidelines for the Safe Use of Machinery, pages 8 to 13. See also guarding requirements for specific plant given in the publication Guidelines for the Safe Use of Machinery.


Seventh-day Adventist Church

Plant Risk Assessment Checklist – Operational Controls (cl.91) & Emergency Stops and Warning Devices (cl.92)


Assessor/s: __________________ __________________ __________________


Name: ____________________________

Serial/Ident No’s: __________________ __________________ ____________________________________ __________________ __________________

Requirement Yes

No


Comment

Are all operational controls suitably identified so that their nature and function is clear?‘On’ coloured green, identified by the word ‘start’ or symbol I. (see below for ‘stop’)Are all operational controls located so as to be operated readily and conveniently by each person using the plant?Within easy reach of operators in their normal working position. The operator should not come within the proximity of moving machine parts when using the switch. Switches should not interfere with adjustments or maintenance of the machine or vice versa.Are all operational controls located or guarded to prevent unintentional activation?No foot-operated start controls. Start buttons should be flush or recessed.Are all operational controls able to be locked in the “off” position (or include an alternative method of power isolation) to enable all motive power and forces to be disconnected?To safeguard against inadvertent operation during maintenance or repair or, in the case of class rooms, unauthorised use.Where it is not reasonably practicable for the plant to be stopped during maintenance and cleaning, is it provided with operational controls that allow safe controlled operation?Where plant is designed to be operated or attended by more than one person and more than one control is fitted to the plant, are the controls of the “stop and lock-off” type so that the plant cannot be restarted after a stop control has been used unless each stop control is reset?Where warning devices are necessary to secure safety, are they placed in a position that serves that purpose?Are emergency stop devices prominently, clearly and durably marked and immediately accessible to each operator?Are emergency stop devices provided with handles, bars or push buttons that are coloured red?Are emergency stop devices unable to be affected by electrical or electronic circuit malfunction?

Further Assistance With Operational Controls, Including Emergency Stops and Warning DevicesGuidelines for the Safe Use of Machinery, pages 26 to 29.



Plant Risk Assessment Checklist – Installation, Erection and Commissioning (cl.136)


Assessor/s: __________________ __________________ __________________


Name: ____________________________

Serial/Ident No’s: __________________ __________________ ____________________________________ __________________ __________________

Requirement Yes

No


Comment

Is plant erected, installed or commissioned having regard to the instructions of the designer and manufacturer, or to instructions developed by a competent person, in so far as they relate to health and safety?Is plant installed, erected or commissioned by a competent person who has been provided with all information necessary to enable the plant to be installed and commissioned safely?Is the plant installed, erected and commissioned in a location that is suitable for the operation being undertaken and the type of plant being used?Is plant designed to be operated in a fixed position positioned on and, if necessary, fixed to, a secure base in order to prevent inadvertent movement when power is applied or while the plant is in operation?Is there sufficient clear space around the plant to allow it to be used and repaired?Guidelines for the Safe Use of Machinery provides, for each plant item contained, recommended spatial allowances.Is there sufficient space for access to and egress from parts of the plant that require cleaning and maintenance?Are emergency lighting, safety doors and alarm systems provided if access to plant is required as part of normal operation and persons may be trapped and exposed to increased risk due to heat, cold or lack of oxygen?Are interim safeguards used during testing of the final means of safeguarding are not in place?So far as can be determined by commissioning, is the plant safe for transfer into active service?


Plant Risk Assessment Checklist – Particular Risk Control Measures (cl.136)



Assessor/s: __________________ __________________ __________________


Name: ____________________________

Serial/Ident No’s: __________________ __________________ ____________________________________ __________________ __________________


Requirement Yes

No


Comment

Do operators receive adequate information, training and supervision to the extent necessary to minimise the risks to health and safety?Is plant only used for the purpose for which it was designed unless a competent person has made an assessment that the change in use does not present an increased risk to health or safety?If safety features or devices are incorporated into the plant, are they used as intended?If it is not possible to eliminate the risk of entanglement in plant with moving parts, are persons prevented from operating or passing in close proximity to the plant unless the risk is controlled by guarding that meets the requirements of the regulations, cl. 90(1) (See Plant Risk Assessment Checklist – Guarding) or the use of a safe system of work? If it is not possible to eliminate the risk of parts of the plant or work pieces breaking, disintegrating or being ejected from the plant, are persons prevented from operating or passing in close proximity to the plant unless the risk is controlled by guarding that meets the requirements of the regulations, cl. 90 (3)? (See Plant Risk Assessment Checklist – Guarding)Are persons prevented from working between fixed and traversing parts of the plant if there is a risk to health or safety?If plant can be remotely or automatically energised and become a risk to health and safety:

is the immediate operating area of the plant designated as a restricted space and access to it controlled at all times? and

persons are prevented from working in the immediate operating area of the plant unless appropriate controls and systems of work are used?

Are persons prevented from working in the immediate vicinity of plant that could start without warning and cause hazards unless appropriate controls and systems of work are in place?Are pipes and other parts of plant that may become hot and expose persons to risk adequately guarded or insulated?Are pipes and other parts of plant that may become cold and expose persons to risk adequately guarded or insulated?Are fixed sources of heat, such as furnaces, coke ovens and cooling racks, ventilated?Are measures provided to prevent, as far as practicable, unauthorised interference with or alteration or use of plant that may make the plant a risk to health or safety?Is plant subject to appropriate checks, tests and inspections necessary to minimise risks to health and safety?If the operation or condition of plant presents an immediate risk to health or safety, is it withdrawn from operation until the risk is eliminated, or if this is not practicable, reasonably controlled?



Plant Risk Assessment Checklist – Inspection and Repair (cl.137)


Assessor/s: __________________ __________________ __________________


Name: ____________________________

Serial/Ident No’s: __________________ __________________ ____________________________________ __________________ __________________

Requirement Yes

No


Comment

Are the necessary facilities and systems of work provided and maintained so as to minimise the risks to health and safety of persons maintaining, inspecting, altering, repairing or cleaning the plant?Are inspections, maintenance and cleaning carried out having regard to procedures recommended by the designer or manufacturer, or developed by a competent person?Are all safety features and warning devices maintained and tested?If plant has been damaged to the extent that its operation or condition is impaired and the risk to health or safety is increased, does a competent person assess the damage and provide advice on:

the nature of the damage? and whether the plant is able to be repaired and, if so, what

repairs must be carried out to minimise risks to health and safety?

Is repair, inspection and, if necessary, testing, carried out by a competent person?Are repairs to the plant carried out so as to keep the plant within its design limits?If access to plant is required for maintenance, cleaning or repair, is the plant stopped and one or more of the following measures used to ensure safety:

lockout or isolation devices? danger tags? permit to work systems? other control measures?

If it is not practicable to carry out cleaning or maintenance with the plant stopped, are operational controls that permit controlled movement of the plant fitted and safe systems of work used?



Plant Risk Assessment Checklist – Dismantling, Storage and Disposal (cl.138)


Assessor/s: __________________ __________________ __________________


Name: ____________________________

Serial/Ident No’s: __________________ __________________ ____________________________________ __________________ __________________

Requirement Yes

No


Comment

If plant is dismantled, is it dismantled by a competent person?Is all available information provided to the employer by the designer or manufacturer relevant to the dismantling of the plant made available to the competent person?If plant, including plant that is to be dismantled, is to be stored, is it stored by a competent person?If plant contains materials that present a risk to health or safety and the plant is to be disposed of, is the disposal carried out by a competent person?



Plant Risk Assessment Checklist – Powered Mobile Plant (PMP) (cl.142)


Assessor/s: __________________ __________________ __________________


Name: ____________________________

Serial/Ident No’s: __________________ __________________ ____________________________________ __________________ __________________


Requirement Yes

No


Comment

Is PMP used in a way that minimises the risk of overturning or a falling object coming in contact with the operator?Where there is a risk of:

PMP overturning; or an object falling on the operator; or an operator being ejected from the seat;

are an appropriate combination of operator protective devices provided, used and maintained?Where there is a risk of PMP colliding with pedestrians or other PMP have appropriate controls been implemented and maintained to prevent or minimise the risk?If a tractor designed to have a mass of 560 kg or more but less than 15,000 kg is in use, is it securely fitted with a roll-over protective structure (ROPS) that conforms to the relevant part of AS 1636?

AS 1636 Tractors – Roll-over protective structures – Criteria and tests (Parts 1-3).All tractors manufactured, imported or originally purchased after 1981 must be fitted with a ROPS that complies with the appropriate section of the Standard. Tractors manufactured, imported or originally purchased prior to 1982 must be fitted with a ROPS that complies with the appropriate section of the Standard or, where such a structure is unavailable, a structure designed by a suitably qualified engineer having regard to the performance requirements of the relevant Standard.If the tractor is used in a place that is too low for it to work while the ROPS is fitted, is the structure lowered or removed only for the period during which the tractor is used in such a situation and only if other measures to minimise risk of roll-over or harm from falling objects are in place?Where:

PMP is fitted with a ROPS or a falling object protective structure, and

attachment points for the seat restraints have been incorporated in the original design of the plant,

are the seat restraints are fitted?Is PMP fitted with warning devices appropriate to effectively warn persons who are at risk from movement of the plant?


Requirement Yes

No


Comment

Is it ensured that PMP is not used to carry, lift, or lower a person other than the operator unless:

the plant was specifically designed to carry persons? and

if the plant includes a specifically designed seat for carrying a passenger, the person is seated in the seat? and

the seat is fitted with appropriate seat restraints? and the seat is located within a zone of protection afforded

by operator protective devices?Are industrial lift trucks equipped with appropriate lifting attachments specifically designed for the load to be lifted or moved?Are industrial lift trucks used in a way that minimises exposure to the operator to risks arising from work practices or systems and the particular environment in which the industrial lift truck is used?



Plant Risk Assessment Checklist – Plant Designed to Lift or Move (cl.142)


Assessor/s: __________________ __________________ __________________


Name: ____________________________

Serial/Ident No’s: __________________ __________________ ____________________________________ __________________ __________________

Requirement Yes

No


Comment

Is a clearly legible notice affixed in a conspicuous place on all lifts or any lifting machinery, specifying the rated capacity of the plant in appropriate metric units or maximum number of persons to be lifted, as may be appropriate?Is it ensured that, so far as is practicable, no loads are suspended or travel over any person?Is it ensured that plant that is not specifically designed for lifting or suspending loads is not used for those tasks unless the plant provides at least an equal level of safety to that of plant specifically designed for those tasks?Is all lifting or suspending done within the rated capacity of the plant?Is it ensured that persons are not lifted or suspended by plant or an attachment to plant (other than plant specifically designed for the purpose) unless:

use of another method of lifting or suspending is not reasonably practicable? and

a suitable and adequate personnel box or carrier, designed for the purpose, is used and is securely attached to the plant? and

means are provided by which persons being lifted or suspended can have safe egress from the personnel box, carrier or plant in the event of a failure in the normal operation of the plant? and

the plant is suitably stabilised, and can be maintained by the operator in that state, at all times during which the personnel box or carrier is in use? and

a suitable fall arrest device is provided to and worn by all persons who are suspended in a personnel box or carrier unless the box or carrier is fully enclosed? and

in the case of a crane, the crane has drive-up and drive-down controls on both the hoisting and luffing motions and these controls are used by the operator in the lifting and suspending operations?



Plant Risk Assessment Checklist – Employer to Provide Information (cl.144)


Assessor/s: __________________ __________________ __________________


Name: ____________________________

Serial/Ident No’s: __________________ __________________ ____________________________________ __________________ __________________

Requirement Yes

No


Comment

Are persons involved in the commissioning, installation, use and testing, and the de-commissioning, dismantling and disposal of plant with all available information concerning health and safety about the plant?Is all relevant information on emergency procedures relating to plant displayed in a manner that can be readily observed by persons who may be exposed to risks arising from the operation of the plant?Where the design of plant for use at work is contracted out is the person engaged to design the plant provided with all relevant information about matters relating to the plant that may affect health or safety?


plant safety checklist

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