equipment safeguarding - anmar std/safeguard powerpoint.pdf · safe working habits that does. ......

EQUIPMENT SAFEGUARDING

LG Rev 21 Feb 11Including

Preventing Fires and Explosions resulting from Hot

WorkPRESENTED BY

REVIEWED JULY 2012


REMEMBER THAT SAFETY RULES, EQUIPMENT AND OTHER SAFETY

MEASURES DO NOT IN THEMSELVES, PROTECT YOU AND THOSE AROUND

YOU.IT IS CONTINUOUS VIGILANCE AND SAFE WORKING HABITS THAT DOES.

EQUIPMENT SAFEGUARDINGAT THE END, THE

FINAL RESPONSIBILITY

FOR YOUR SAFETY IS IN YOUR OWN

HANDS!


WE THEREFORE REQUEST THAT YOU MAKE YOURSELF CONVERSANT WITH THIS GUIDE SO THAT YOU MAY OBTAIN THE KNOWLEDGE THAT WILL ASSIST YOU TO GUARD AGAINST PERSONNEL INJURY WHILE WORKING AT ANGLO PLATINUM SMELTERS.


GOLDEN RULES FOR EQUIPMENT SAFEGUARDING

Good communication must always convey awareness to all the team

members

EQUIPMENT SAFEGUARDINGGOLDEN RULES FOR EQUIPMENT

SAFEGUARDING

Remember no work is so Important and Urgent that it should be conducted in an unsafe manner.

EQUIPMENT SAFEGUARDINGSection 1

MHSA Requirements

Regulation 8.8(1)

The employer must take reasonable and practicable measures to prevent persons from being injured as a result of them, the cloths being worn by employees or any equipment being held by them coming into contact with or being drawn into any moving part of any machine.

EQUIPMENT SAFEGUARDINGCHAPTER 20

MINERALS ACT REGULATIONS

Regulation 20.5

All exposed machinery which, when in motion, may be dangerous to any person shall be securely fenced off. Efficient guards shall be provided to such parts of any machinery as may be a source of danger to any.


Act 15 of the OHSA.

DUTY NOT TO INTERFERE WITH, DAMAGE OR MISUSE THINGS

No person shall intentionally or recklessly interfere with, damage or misuse any thing which is provided in the interest of health or safety.

EQUIPMENT SAFEGUARDINGOHSA.

GENERAL MACHINERY REGULATIONSSafeguarding of machinery(a) Every employer or user of machinery

shall-ensure that all machinery used by him, is suitable for the purpose for which it is used, and that it is installed, operated and maintained in such a manner as to prevent the exposure of persons to hazardous or potentially hazardous conditions or circumstances

EQUIPMENT SAFEGUARDINGOHSA.

GENERAL MACHINERY REGULATIONSSafeguarding of machinery(b) In particular cause every exposed and

dangerous part of machinery which is within the normal reach of persons to be effectively safeguarded by means of insulators, fencing, screening or guarding, except where an inspection has granted written permission for the omission of such safeguarding


New Plant and Equipment.

Anglo Platinum Smelters have recognized the fact that exposed moving parts of machinery must be kept to a minimum.

THEREFORE


Suppliers of Machinery were requested to consider every possible means whereby the need for a guard to prevent contact with exposed moving machinery can be eliminated wherever possible.

This can only be achieved by eliminating the moving components that require guarding.



How can this be achieved?

Examples of how it can be achieved are as follows:

Hydrostatic drive systemsDirect coupling of external casings with

internal drive shaftsMotorized drums Etc.


Continuous Improvement.

Engineering staff must consider the replacement of existing guard arrangements with drive systems with no external moving parts to which people can be exposed.


Plant and equipment safeguarding

Anglo Plats Smelters have recognized the fact that guarding moving parts of machinery, is not only a legal requirement, but an essential requirement to comply to our value of:

Preventing injuries byPUTTING SAFETY FIRST!!!


Guards Designed and Installed to prevent contact with moving parts

Guards are often designed and installed around the moving parts of machinery to prevent contact with the moving parts and subsequent injury.

THEREFORE


It is essential that any guard fitted to prevent contact with moving machinery parts must prevent contact by reaching:

• Upwards towards the moving part• Under the guard• Over the guard• Into the guard• Around the guard• Through the guard


Examples of unsafe Machine Guards


Section 4

Anglo Plats Smelters have standardized on a simple set of guarding design standards that meets all the recommendations for equipment guarding. These guards are effective and easy to maintain.

EQUIPMENT SAFEGUARDINGAppendix 1

EQUIPMENT SAFEGUARDINGSection 5.1

Maintenance of Installed Guarding.

Once equipment guarding has been designed and installed, it obviously has to be well maintained in order to ensure the effectiveness for its purpose.


Each Smelter operation has a planned maintenance system that will call for the periodic inspection of machine guarding.

Damaged guards must be repaired immediately when detected.


Managers and Supervisors must carry out audits and over inspections on maintenance work carried out in order to ensure the ongoing effectiveness of machinery guards.


REMEMBER the following NEVERSwhen doing maintenance on Machine Guarding:

When maintaining a machine guard, always check and make sure that the guard complies with the Smelter Standard for guards (Appendix 1).


Never remove a guard to do a job without making sure that the moving machinery you areabout to work on has been isolated and locked-out.


Section 5.6

Before removing a guard, always check for stored energy that could cause injury by inadvertently setting machinery parts into motion – all stored energy must also be isolated and locked-out.


Section 5.7

NEVER REMOVE a guard to do a job without replacing the guard after the job has been completed.


NEVER MODIFY a guard unless the Responsible Engineer has approved the modification aspart of an approved design change.


NEVER cut away a section of a guardbecause it makes your job easier to perform.

Do not cut a hole into a guard to quickly check “V” belt tension between pulleys (or for any other seemingly convenient purpose e.g. Lubricating) because this causes the guard to be ineffective in its purpose – always remove the guard and replace it in an effective condition after checking the “V” belt tension or when equipment was lubricated. Etc.



SECTION 6

Interlocking Systems to Prevent Contact with Moving Machinery Parts

EQUIPMENT SAFEGUARDINGChapter 21

Minerals Act Regulations

Regulation 21.4

No person shall interfere with or render ineffective any electrical apparatus provided for safety or protection unless it is necessary to do so to perform work associated with such apparatus.


Certain machines are designed, assembled and commissioned to run inside an enclosure that places the moving parts of the machine in a position where contact with the moving parts cannot be made because of the protection offered by the enclosure.

i.e. Screw Compressors, Automated Metallurgical Dewatering Filter Press (Larox) systems etc.


Interlocking 2

The above systems are permitted but the moment a protective cover is removed or gate is opened to the extent that access to moving parts becomes possible, a limit switch or other sensing device must cause the machine to trip out and come to a stop.


Interlocking 3The design of such a machine must ensure that all moving parts are stationary before any person can come into contact with such parts and cause injury to himself/herself.


Interlocking 4

The reliability of the aforementioned machine tripping devises must be maintained and such devices may not be bridged out or made inoperable under any circumstances.

EQUIPMENT SAFEGUARDINGSection 7: Temporary removal of guarding.

Where the temporary removal of guarding or other safeguard/s becomes necessary on operating plant and equipment, for the purpose of maintenance, inspection, fault finding, testing, commissioning or for any other reason,


Temporary removal of guarding 2.

A pre-work HIRA must be carried out for such work.

Written permission must be obtained from the Responsible Engineer.

Guards shall be replaced prior to such plant and equipment being put back into operation again.

EQUIPMENT SAFEGUARDINGREMEMBER 1:

Never work on moving equipment that has not been isolated and locked out!


A guard must always be replaced before machinery is allowed back into operation.


A works order must always be generated and a pre-work HIRA must always be carried out for work requiring the removal of a guard – even if this work is part of operational requirements (see Isolation, Lock-Out and Clearance to Work Code – Section 10.6.1).

EQUIPMENT SAFEGUARDINGLock-Out and Clearance to Work

Code – Section 10.6.1).

An approved Works Order (job card) must be generated for all work before any person is assigned responsibility to ensure that the work is carried out.


Code – Section 10.6.1).The aforementioned work includes:(i) Maintenance and Repair Work(ii) Installation and commissioning

work(iii) Building and construction work

EQUIPMENT SAFEGUARDINGLock-Out and Clearance to

Work Code – Section 10.6.1).(iv) Any other work for which a routine

operating procedure has not been developed including (but not restricted to) work necessitating the temporaryremoval of guarding, cleaning, washing down, the removal/disposal of spillage, rubble, slurry or residue.


Code – Section 10.6.1).

Provided that: all work for which a works order is generated must be considered non-routine work in terms of AFRS requirements for non-routine work.

EQUIPMENT SAFEGUARDINGSection 8.1Access Control

Access Control Requirements where Guarding and Interlock Systems are Insufficient to Protect People.

EQUIPMENT SAFEGUARDINGSection 8.2:

There is so much industrial activity taking place in a Smelter that the need to protect persons from harm by restricting their entry into areas that may be unsafe to them is essential.

The following methods are used to control entry and prevent persons from entering into a place where they may be inadvertently exposed to danger:


(a) Electronic sensing and recording of entry:

This method is normally applied at the main access points into a Smelter or other area of(i.e. a clock card allowing entry through a turnstile) or other area within a Smelter wherethe number of persons requiring entry at any time necessitates such a method of control.

EQUIPMENT SAFEGUARDINGSection 8: Access Control 4

In such a case, the reason/s for preventing entry would be to filter out and prevent the entry of persons:

Who have not undergone induction and are therefore not aware of site rules and PPE requirements.

Who are not in possession of a mandatory medical certificate of fitness.

Persons who have failed to renew their medical or induction certificates on time.

Persons who are excluded from entry by management.i.e. persons who have been suspended and face disciplinary action etc.

EQUIPMENT SAFEGUARDINGSection 8.5:

By the same token:Persons who are required to be within a Smelter

area at any time, who are aware ofthe rules for entry and comply with such rules are allowed entry.

A record is automatically made of all persons who enter and leave such an area: this capability is very important because it also provides an immediate record of who isinside the operational area at any time.


Electronic sensing and recording of entry is also used for controlling and restrictingaccess into certain sections of the operation to specified persons.


b) Confined Space or High Risk Location Entry Permit

The Issue of which is dependent on (risk based) requirements for ensuringsafe access to these High Risklocations e.g. for allowing entry into a Confined Space or High Risk location.


This method of Equipment Safe Guarding is used to control entry into areas or locations that are known to have a high risk upon entry and for which a

“CONFINED SPACE OR HIGH RISK LOCATION ENTRY PERMIT IS

REQUIRED”

ISOLATION RECORD

BOOK


Entry into these areas will require the Occupational hygienist or other competent and authorized person to declare the atmosphere and environment therein safe before any person is allowed to enter because:


There may not been sufficient oxygen-Solid or particulate material may fall-It may contain water or slurry-You can fall due to slipperiness and

inadequate support-May contain poisonous fumes or

gasses-There may be explosive or flammable

gasses or substances present-It may be to hot or to cold inside-


There may also be other Hazards inside confined space or High Risk Location therefore the Engineering Foreman/Supervisor in charge is required to facilitate a HIRA before entry is allowed into any Confined or High Risk Location.


There should always be a sign at the entrance to a Confined Space or High Risk Location warning people to this effect.

Confined Space / High Risk Location

EQUIPMENT SAFEGUARDINGNEVER ENTER A CONFINED SPACE OR

HIGH RISK LOCATION UNLESS:The responsible Occupational

Hygienist has declared the atmospheretherein safe for entry.A HIRA has been carried out for the

work inside the Confined Space or High Risk Location.

EQUIPMENT SAFEGUARDINGYou know the precautions to be taken

to protect your safety and the safety of your team members when you enter the location.You have been issued with a Confined

Space or high Risk Location Entry Permit by the Responsible Operator.


c) Locked gate or door with log book records of entry and purpose of entry:This method is generally used where the frequency of entry is not high enough to justifythe cost of installing and maintaining an Electronic Sensing System for controlling entryinto certain restricted areas. However, the importance of controlling entry and recording such entry still remains.

EQUIPMENT SAFEGUARDINGSection 8.8 A typical example, this type of control is when an electrician

enters a medium voltage electrical distribution substation to carry out medium voltage switching.The electrician will enter the substation through a locked door using a key that only he/she is allowed to posses and records the time of entry and reason for entry into a “substation log book”. After completing the intended work, he/she will record the fact that the intended work is completed, the time that he/she leaves the sub station and makes sure that all substation doors are safely locked to keep persons who are not allowed into the substation out of this potentially dangerous area.

EQUIPMENT SAFEGUARDINGSection 8. 9

Another typical example is when a security guard allows a vehicle into a restricted area by pre-arrangement –the guard allows the vehicle to pass through a set of gates that are normally locked after recording the details of the vehicle and the details of driver.

EQUIPMENT SAFEGUARDINGSection 8. 10

c) Signage and Demarcation:This method generally applies to the necessity to warn, inform and /or remind personswho have already been informed that they are not permitted into certain areas.The aforementioned information is usually provided initially during site induction and orientation.

EQUIPMENT SAFEGUARDINGSection 8: Access Control 11

Typical examples of access control by means of signage and demarcation are as follows:

Specific Workshop Areas: Unauthorized Entry Prohibited

Water Storage Areas: Danger of Drowning –Unauthorized Entry Prohibited

Safe Walkways: Danger – Moving Vehicles –Pedestrians Must Use Safe Walkways.


See Appendix 7: Access control assessment for areas where safeguarding and interlock systems are insufficient to protect people.


Fail-to-Safe Switches for Power Driven Tools.i.e.

• Hand held drilling machines, • Saws, • Lathes, • Drill presses, • Pipe threading machines• etc

EQUIPMENT SAFEGUARDINGSection 9.2 Fail safe Switches

(a) Hand Held Portable Power Driven Tools:All hand held portable power driven tools such as hand held drilling machines, hand held grinders, hand held jig saws etc must stop the moment the user releases thepower supply switch.


It is not permitted to use a power driven hand tool that has a button or other devise that overrides the “automatic switching off of power” when the power switch of the tool is released.


(b) Other manually driven power tools that are not hand held such as lathes, pipe threading machines and drill presses must also be fitted with Fail-to-safe power supply switches.


In the case where the power driven tools are not hand held, a foot operated switch is usually provided so that the moment an authorized user steps away from his / her place of attendance on the operation of the machine, the power supply to the machine is automatically switched off and the machine comes to a stop.


Note:No manually operated power tools may be used unless such tools are fitted with Fail-to-Safe power supply switches.

HOT WORK

Preventing Fires and Explosions resulting from Hot Work

RULES FOR PREVENTION OF FIRES AND EXPLOSIONS

DEFINITIONS

Hot workPreventing Fires and Explosions resulting

from Hot WorkAny work which involves or generate a source or potential

source of ignition

PREVENTING FIRES AND EXPLOSIONS RESULTING FROM

HOT WORKExamples of Hot Work

Processes

Electric Arc WeldingGas WeldingFlame CuttingGrindingDrillingHammering

ChippingWire BrushingUse of Non Flame

proof Elect Equip.Heating for Stress

Relieving

PREVENTING FIRES AND EXPLOSIONS RESULTING FROM HOT WORK

RULES FOR PREVENTION OF FIRES AND EXPLOSIONS

HOT-WORK PROCEDURES AND CLEARANCE CERTIFICATE PROCEDURES MUST BE FOLLOWED

HOT WORK WILL NOT BE CONDUCTED WITHOUT AN APPROPRIATE PRE-WORK HIRA DONE

PREVENTING FIRES AND EXPLOSION RESULTING FROM

HOT WORKRULES FOR PREVENTION OF FIRES

AND EXPLOSIONS

ALL PERSONS MUST BE TRAINED AND BE COMPETENT FOR THE WORK THEY CONDUCT.

PPE WILL BE WORN AS DETERMINED BY THE HIRA AND MINIMUM SITE REQUIREMENTS

PREVENTING FIRES AND EXPLOSION RESULTING FROM HOT WORK

Which PPE will you need when conducting the following types of Hot Work?:

List the PPE when:Grinding:………………………………………Flame Cutting:………………………………..Arc Welding :………………………………..Flame Welding/Brazing:……………………..…………………………………………………

PREVENTING FIRES AND EXPLOSION RESULTING FROM HOT

WORK RULES FOR PREVENTION OF FIRES

AND EXPLOSIONS EMERGENCY RESPONSE PLANS, WILL

BE IN PLACE BEFORE COMMENCEMENT OF THE WORK

ZERO TOLERANCE MEANS STOPPING WORK THAT IS UNSAFE. WHEN IN DOUBT STAY OUT.


LIST THE EMERGENCY RESPONSE PLANS THAT YOU WILL PUT IN PLACE BEFORE YOU START WITH HOT WORK IN A WORK PLACE. ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………


WORKQuestions to be asked before you start

with HOT WORK

Only persons trained and competent , may conduct HOT WORKWhat can Burn or Explode when I’m

going to do HOT WORK?What is on the Inside or Other side?


WORK Questions to be asked before you start

with HOT WORK ( Cont)

Will I be able to extinguish a fire should it now occur?

Is there enough ventilation where I’m going to work?

Do I wear the correct PPE?


WORK

REMEMBER A SMALL SPARK LEFT

UNATTENDED CAN BURN DOWN A

FOREST

DEFINITIONS

Clearance to Work Permit

A Permit, issued in accordance with an approved format by the Responsible Operator, allowing work (called for by a Works Order) to be carried out.

DEFINITIONS

Hazard

A source of or exposure to danger (MHSA).

DEFINITIONS

Risk

The likelihood that occupational injury or harm to persons will occur (MHSA).

DEFINITIONS

Works Order

A written order calling for work, issued in accordance with a procedure for the issuing of Works Orders, that is approved and implemented by the Responsible Manager and Engineer.

DEFINITIONS

Clearance to Work Permit

A Permit, issued in accordance with an approved format by the Responsible Operator, allowing work (called for by a Works Order) to be carried out.

DEFINITIONS

CERTIFICATE TO CONDUCT HOT WORK

A Certificate or License issued to a person who becomes competent to take part in HOT WORK operations by virtue of training received.

DEFINITIONS

DESIGNATED AREA

Places which have been specificallydesignated and equipped to perform HOTWORK without the risk of fire or Explosions caused by the hot work activity

DEFINITIONS

De Contamination

To make safe from any Hazard whichcause a risk to the safety of personswho had to perform work in the area.


WORK Procedure 1The Responsible Operator may give permission for Hot Work to be carried out by the Responsible Artisan/Person (issue a Hot Work Permit) within his/her area of authority by signing the “Hot Work Permit” section of a Clearance to Work document.


WORK Procedure 2Before signing the aforementioned “Hot Work Permit Section”, the Responsible Operator must ensure, as far as reasonable practicable, that the person/s about to carry out welding, flame cutting, grinding or any other type of Hot Work have:


HOT WORK i. Taken the necessary precautions to

ensure that the Hot Work does not take place in the presence of an oxygen enriched atmosphere likely to enhance combustion, explosive or combustible liquid, vapour, or dust


WORK ii. Ensured that areas, surfaces, bins or

vessels used for the storage or processing of combustible materials in solid or particulate form, affected by the Hot Work, have been cleared and cleaned of all such material, including any dust that may have generated by the handling or processing of such material.


WORK iii. Ensured that pipes, vessels or other equipment

used to contain (or are likely to contain) an oxygen enriched atmosphere, explosive or combustible liquids, vapour, gas or dust; have been cleaned, washed out or purged, according to a procedure approved by the Responsible Engineer (in consultation with the Responsible Occupation Hygienist) and thereafter Isolated and Locked out before Hot Work is carried out on any surface of such equipment.


WORK

Provided that:A test carried out in accordance with a procedure approved by the Responsible Occupational Hygienist on the atmosphere affected by the Hot Work, indicates that it is safe to proceed with the Hot Work.


iv. Ensured (by checking) that any type ofHot Work does not inadvertently take place on the outer surface of any equipment that may have a rubber, epoxy or other flammable protective liner on its inner/opposite surface and/or that such equipment does not contain a flammable/explosive substance that could be ignited by the heat generated from such work.


WORK Provided that: IV (a) Site specific equipment containing

combustible materials affected by Hot Work should be clearly identifiable assuch by prominent signage;


WORK

IV (b) Site specific equipment containing hazardous substances or materials that may emit hazardous fumes when subjected to heat should be clearly identifiable as such by prominent signage;


WORK IV (c) That procedures specific to such

equipment, are in place to prevent fires, explosions and/or injury when any work is carried out in the vicinity of the aforementioned equipment. i.e.Evaporative coolers, GRP and rubber lined tanks and vessels, bag houses for dust extraction systems etc.


HOT WORK IV (d) the Responsible Engineer must

authorise and specify the conditions under which hot work may be carriedout where it is not possible to removeall combustible liner material adjacent to where Hot Work is required.


WORK (v) Ensured that an excessive build up of

pressure does not take place in any pipe or enclosed vessel resulting fromheat generated by the Hot Work beingcarried out and that any such pipe or vessel is adequately open to atmospherewhile such Hot Work is being carried out.


HOT WORK (vi) Examined all areas affected by the

Hot Work where sparks, splatter from welding or flame cutting or hot metal off-cuts, falling or projected from the position of work, could inadvertently ignite any combustible materials in such areas.


HOT WORK i.e. at the level where the work will be

carried out, as well as all areas below, and that all combustible materials are either removed from the areas affected or where removal is not possible, protected from ignition by means of a suitable fire prevention cover/blanket and/or by wetting down (where wetting down is practical).


HOT WORK REMEMBER:

Site specific equipment containing combustible materials or liners must be identifiable by clear and prominent signage.


WORK(vii) Ensured that where a Hazardous

Substance is normally contained within the equipment on/in which Hot Work is required, the requirements for Hazardous Substance Isolation are complied with and a Hazardous Substance Isolation Permit is issued accordingly, in addition to the Hot Work Permit.


WORK

Provided that:Site specific equipment containing hazardous materials or liners must be identifiable by clear and prominent signage.


WORK(viii) Ensured that where the Hot Work is

required to take place in any Confined Space or High Risk Location, a Confined Space or High Risk Location Entry Permit is issued accordingly, in addition to the Hot Work Permit.


WORK(ix) Prevented inadvertent access to all

areas affected by the Hot Work by barricading off such areas while the HOT Work is being carried out and if necessary, depending on the HIRA controls required, by strategically placing guards in addition to barricading.


WORK(x) Been adequately instructed on the

reactive response measures necessary to deal with an emergency arising from such work including but not limited to the positioning and sounding of fire alarms, the positioning and use of fire suppression systems/fire extinguishers, evacuation procedures, telephone positions and how to call for first aid assistance.


WORKREMEMBER:

The Responsible Operator must refer any confusion or dispute with regard to the requirements for carrying out “Hot Work” to the Responsible Engineer, who may authorise the commencement of work subject to such conditions as he/she may impose. This referral and authorisation must be done in writing on form ALLSM – EPR –STD – 0010 – FRM – 001


WORKxi) Both the Responsible Operator

and Responsible Artisan must ensure that they are familiar with the Smelter Procedure for Preventing Fires and Explosions resulting from Hot Work ALLSM - EPR – PRO –0001.


WORKIsolation code sec 24.2.6 (iii)

Cutting torches, heating torches and/or any other equipment which uses oxygen, flammable gas and/or a flammable substance must be removed, complete with supply hoses, from a confined space when not being used.


As far as is reasonably practicableheating or cutting torches must not be ignited inside the confined space and effective controls must be in place to prevent an inadvertent and/or uncontrolled release of oxygen, acetylene, or any other flammable gas / substance into the confined space at any time.

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