2016 MAY Semester

CDB 1012
Health, Safety & Environment

Mechanical Hazards &

Machine Safeguarding
Lecture 7
DR. NORIDAH BINTI OSMAN

2014 PETROLIAM NASIONAL BERHAD (PETRONAS)

(Course Coordinator)
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Email: noridah.osman@petronas.com.my
1

Learning Outcome
Common Mechanical
Injuries

Requirements for All Safeguards

Lockout/Tagout Systems

Taking Corrective Action

Video

https://www.youtube.com/watch?v=1Cu_QiVW9mM
https://www.youtube.com/watch?v=X4BbgwVJZYA
https://www.youtube.com/watch?v=AFe_0tOgp7M
https://www.youtube.com/watch?v=Mufutf53OYA

https://www.youtube.com/watch?v=kk6OWeplbj8
https://www.youtube.com/watch?v=nhBUF5VChZE
https://www.youtube.com/watch?v=6TBO_PXSby8
https://www.youtube.com/watch?v=hwg8rozgBBQ

OCCUPATIONAL HAZARDS
I. Physical
Hazards
III. Biological
Hazards

II. Chemical
Hazards
IV. Mechanical
Hazards

V. Psychological
Hazards
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MECHANICAL HAZARDS
A harmful or danger posing
situation that involves machines
mostly in a working environment

Mechanical Hazards
Definition
Mechanical hazards are those associated

with power-driven machines,

whether automated or manually operated or it
is a type of general confined space hazard that
exists when electrical or mechanical equipment
may be accidentally activated.

Where Mechanical Hazards

Occur?
Dangerous moving parts in three basic areas
require safeguarding:
The point of operation: that point where work is
performed on the material, such as cutting, shaping, boring,
or forming of stock.
Power transmission apparatus: all components of the
mechanical system which transmit energy to the part of the
machine performing the work. These components include
flywheels, pulleys, belts, connecting rods, couplings, cams,
chains, cranks, and gears.
Other moving parts: all parts of the machine which move
while the machine is working. Include reciprocating,
rotating, and transverse moving parts, as well as feed
mechanisms and auxiliary parts of the machine.

INJURIES - DEFINITION
INJURY
Any harm, whatever illegally caused to any person in
body, mind, reputation or property

ASSAULT
An offer or threat or attempt to apply force to body of
another in a hostile manner

MECHANICAL INJURY (WOUND)

A break of the natural continuity of any of the tissues of the
living body, produced by physical violence

COMMON MECHANICAL INJURIES

Cutting and
Tearing

Straining and
spraining

Shearing

Common Mechanical
Injuries

Puncturing

Crushing

Breaking

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 Crushing they occur when a part of the body is caught between

two hard surfaces that progressively move together, thereby crushing

anything between them; squeeze point & run-in-point
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Common Mechanical Injuries

Breaking a break in a bone is known as
fracture. Fractures are classified as simple,
compound, complete, and incomplete.
Straining & spraining a strain results when
muscles are overstretched or torn. A sprain is
the result of torn ligaments in a joint. Strains &
sprains can cause swelling and intense pain.

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Hazardous Mechanical Motions

Basic types:
Rotating
Reciprocating
Transversing

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 Rotating collars, couplings, cams, clutches, flywheels, shaft

ends, spindles, meshing gears, and horizontal or vertical shafting are

some examples of common rotating mechanisms which may be
hazardous
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 Reciprocating hazardous because, during the

back-and-forth or up-and-down motion, a worker
may be struck by or caught between a moving and
a stationary part

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 Transversing (movement in a straight,

continuous line) creates a hazard because a
worker may be struck or caught in a pinch or
shear point by the moving part

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What must a safeguard

do to protect workers against
mechanical hazards?

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Requirement for Safeguards

Prevent contact - prevent workers body or clothing from

contacting hazardous moving parts

Secure - firmly secured to machine and not easily removed

Protect from falling objects - ensure that no objects can fall

into moving parts

Create no new hazards - must not have shear points, jagged

edges or unfinished surfaces

Create no interference - must not prevent worker from

performing the job quickly and comfortably

Allow safe lubrication - if possible, be able to lubricate the

machine without removing the safeguards

Machine Safeguarding
Classifications

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Methods of Machine Safeguarding

Guards
fixed
interlocked
adjustable
self-adjusting

Location/distance

Feeding and ejection methods

automatic and/or semiautomatic feed and
ejection
robots

Devices
presence sensing
Miscellaneous aids
pullback
awareness barriers
restraint
protective shields
safety controls (tripwire cable,
hand-feeding tools
two-hand control, etc.)
gates

Fixed Guard
Provides a barrier - a permanent part of the machine,
preferable to all other types of guards.

Fixed Guards - Provides a

barrier
Advantages

Can be constructed to suit

many specific applications
In-plant construction is
often possible
Can provide maximum
protection
Usually requires minimum
maintenance
Can be suitable to high
production, repetitive
operations

Limitations

May interfere with visibility

Can be limited to specific
operations
Machine adjustment and
repair often require its
removal, thereby
necessitating other means
of protection for
maintenance personnel

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Safety Devices
Stop the machine if a hand or any part of the body is
inadvertently placed in the danger area;
Restrain or withdraw the operator's hands from the
danger area during operation;
Require the operator to use both hands on machine
controls, thus keeping both hands and body out of
danger; or
Provide a barrier which is synchronized with the
operating cycle of the machine in order to prevent
entry to the danger area during the hazardous part of
the cycle.

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Pullback Device
Utilizes a series of
cables attached to the
operators hands,
wrists, and/or arms

Primarily used on
machines with stroking
action
Allows access to the
point of operation when
the slide/ram is up
Withdraws hands when
the slide/ram begins to
descend

Safeguarding by Location/Distance
Locate the machine or
its dangerous moving
parts so that they are not
accessible or do not
present a hazard to a
worker during normal
operation
Maintain a safe distance
from the danger area

Robots
Machines that load
and unload stock,
assemble parts,
transfer objects, or
perform other tasks
Best used in highproduction
processes requiring
repeated routines
where they prevent
other hazards to
employees

Machine Safeguarding
Classifications

Guards
Fixed
Interlocked
Adjustable
Self-adjusting
Devices
Presence Sensing
Photoelectric
(optical)
Radiofrequency
(capacitance)
Electromechanica
l
Pullback
Restraint

Safety Controls
Safety trip control
Pressuresensitive body
bar
Safety tripod
Safety tripwire
cable
Two-hand control
Two-hand trip
Gates
Interlocked
Other
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Machine Safeguarding
Classifications
Location/Distance
Potential Feeding and
Ejection Methods
Automatic feed
Semi-automatic feed
Automatic ejection
Semi-automatic
ejection
Robot

Miscellaneous Aids
Awareness barriers
Miscellaneous protective
shields
Hand-feeding tools and
holding fixtures

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Machine Safety
Responsibilities
Management
ensure all machinery is properly guarded

Supervisors
train employees on specific guard rules in their areas
ensure machine guards remain in place and are functional
immediately correct machine guard deficiencies

Employees
do not remove guards unless machine is locked and tagged
report machine guard problems to supervisors immediately
do not operate equipment unless guards are in place

Methods of Machine Safeguarding

Guards
Fixed guards a permanent barrier between
workers and the point of operation
Interlocked guards shut down the machine
when the guard is not securely in place or is
disengaged
Adjustable guards provide a barrier against
a variety of different hazards associated with
different production operations.

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Robot Safeguarding
The main hazards associated with robots are: (1)
entrapment of a worker between a robot and a solid
surface; (2) impact with a moving robot arm; and (3)
impact with objects ejected or dropped by the robot.
The best guard against these hazards is to erect a
physical barrier around the entire perimeter of a
robotss work envelope (the three-dimensional area
established by the robots full range of motion). This
physical barrier should be able to withstand the force of
the heaviest object the robot could eject

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Lockout
Placement of a lockout device on an energy
isolating device, in accordance with an
established procedure, ensuring that
energy isolating device and equipment being
controlled cannot be operated until lockout
device is removed

Lockout device
Device that uses a
positive means such as
a lock, either key or
combination type, to
hold an energy isolating
device in the safe
position and prevent the
energizing of a machine
or equipment
Blank flanges and bolted
slip blinds included

Tagout
Placement of tagout device
on an energy isolating device,
in accordance with an established
procedure,
to indicate that energy
isolating device and
equipment being controlled
may not be operated until
tagout device is removed

TAG-OUT/LOCK-OUT SYSTEM

Class Activity 7.5

What is lock-out/tag-out systems?
What is the purpose of lack-out/tag-out systems?
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OSHAS LOCK-OUT/TAG-OUT
SYSTEM
Energy control program: Organizations must

have an energy control program that have fully

documented energy control procedures, provide
employee training, and ensure periodic inspections.
Energy control procedure: a statement on how
the procedure will be used; procedural steps to shut
down, isolate, block, and secure machines or equipment;
steps designating the safe placement, removal and
transfer of lockout/tagout devices and responsible
person; specific requirements for testing machinery or
equipment.
Energy-isolating devices: for preventing the
accidental or inadvertent release of energy on all
machines and equipment. Device must be able to be
locked out/ tagged out.

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OSHAS LOCK-OUT/TAG-OUT
SYSTEM
1. Requirements for lockout/tagout devices:
durable to withstand the environment to which they
will be exposed.
1. Employee training: provide initial training and
retraining as required and certify that necessary
training has been given to all employees
(authorized, affected and other).
1. Periodic inspections: At least annually, and
certify the inspections have taken place.

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OSHAS LOCK-OUT/TAG-OUT
SYSTEM ..CONT
4. Applications of controls and lockout/tagout
devices: follow appropriate procedure.
4. Removal of Locks or tags: follow appropriate
procedure.
4. Additional safety requirements: follow specific
procedure.

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EVALUATING LOCK-OUT/TAG-OUT
PROGRAMS
1. Are all machinery or equipment capable of
movement required to be de-energized or
locked out during cleaning, servicing, adjusting
or setup operations.
2. Are all equipment control valve handles
equipped with a means for locking out.
3. Does lockout procedure require that all stored
energy be released or blocked before the
equipment is locked out.
4. Are employees required to check the safety
lockout by attempting a startup after making
sure no one is exposed.
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EVALUATING LOCK-OUT/TAG-OUT
PROGRAMS.. CONT
5. After the safety is checked does the
employee again place the switch in the off
position.
6. Have employees been trained not to start
machinery if it has been locked out or tagged
out.
7. Are all workers notified when machinery or
equipment they usually use is shut down and
locked out for maintenance or servicing
purposes.
8. Before machine is activated are employees
notified.
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RISK ASSESSMENT IN MACHINE

OPERATION
Quantifying the level of risk associated with
the operation of a given machine:
Severity of potential injuries (S):
S1 Slight injury (bruise, abrasion)
S2 Severe injury (amputation or death)
Frequency of exposure to potential hazards
(F):
F1 Infrequent exposure
F2 Frequent to continuous exposure

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RISK ASSESSMENT IN MACHINE

OPERATION.. CONT
Quantifying the level of risk associated with
the operation of a given machine:
Possibility of avoiding the hazard if it does
occur (P):
P1 Possible
P2 Less possible to not impossible
Likelihood that the hazard will occur (L):
L1 Highly unlikely
L2 Unlikely
L3 Highly likely
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SUMMARY
1. The most common mechanical injuries
are cutting and tearing.
2. Safeguarding involves devices or
methods that minimize the risk of
accidents resulting from machineoperator contact.
3. OSHA standard for machine guarding is
29CFR 1910.212.

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SUMMARY
4. The best safeguard for a robot is a
barrier around the perimeter of its
work envelope.
5. Lockout/tagout is designed to
prevent injuries from the accidental
energizing of machines or equipment
while they are shut down for
maintenance or servicing.
6. When hazards or hazardous behavior is
observed corrective action should be
taken immediately.

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STEP FOUR: SET REASONABLE

OBJECTIVES

If we pull this off, well eat like kings!

Thank you