c05_work_equipment_general_COMPLETE

Question 1

The suitability and safety of work equipment is considered from three aspects:

Answer 1

(a) its initial integrity (b) the place where it will be used (c) the purpose for which it will be used.

Question 2

Ergonomics is concerned with

Answer 2

the interaction of humans and other elements of a system, and the design of such systems in order to optimise human well-being and overall system performance.

Question 3

Under the intended conditions of use, the discomfort, fatigue and physical and psychological stress faced by the operator must be reduced to the minimum possible, taking into account ergonomic principles such as: 5

Answer 3

 allowing for the variability of the operator’s physical dimensions, strength and stamina  providing enough space for movements of the parts of the operator’s body  avoiding a machine-determined work rate  avoiding monitoring that requires lengthy concentration  adapting the man/machinery interface to the foreseeable characteristics of the operators.

Question 4

Effective work equipment controls should be designed to be 3

Answer 4

accessible, identifiable and usable.

Question 5

Where it is necessary to provide an opening in a guard, it should be at a sufficient distance to prevent any person from reaching the hazard. This may be achieved by: 2

Answer 5

 positioning the guard at the required distance  providing a tunnel which extends outwards from it.

Question 6

The Provision and Use of Work Equipment Regulations 1998

Answer 6

4.Suitability of work equipment5.Maintenance6.Inspection7.Specific risks8.Information and instructions9.Training10.Conformity with Community requirements11.Dangerous parts of machinery12.Protection against specified hazards13.High or very low temperature14.Controls for starting or making a significant change in operating conditions15.Stop controls16.Emergency stop controls17.Controls18.Control systems19.Isolation from sources of energy20.Stability21.Lighting22.Maintenance operations23.Markings24.Warnings

Question 7

Adequate initial integrity is ensured by adherence to the following engineering principles: 7

Answer 7

 Identification of risks implicit in the design.  Understanding of operating and fault conditions, material properties and potential failure modes.  Risk minimisation through a hierarchical approach.  Adherence to suitable design principles (as embodied in BS EN’s or industry standards).  Testing of load-bearing structures.  Use of suitable materials.  The provision of active safety features with demonstrably adequate reliability, availability and survivability.

Question 8

The continuing integrity of work equipment throughout its service life is ensured by: 4

Answer 8

 Using / operating it within the limits for which it was designed.  Appropriate maintenance.  Periodic inspection and testing.  Procedures to prevent unauthorised modifications.

Question 9

Regulation 12 of PUWER requires every employer to take measures to ensure that the exposure of a person using work equipment to any risk to his health or safety from any of the following hazards is either prevented, or, where that is not reasonably practicable, adequately controlled. 7

Answer 9

 Material falling from equipment … for example a loose board falling from scaffolding, a straw bale falling from a tractor fore-loader or molten metal spilling from a ladle.  Material held in the equipment being unexpectedly thrown out … for example: swarf ejected from a machine tool.  Parts of the equipment breaking off and being thrown out … for example: an abrasive wheel bursting.  Parts of the equipment coming apart … for example: collapse of scaffolding or falsework.  Overheating or fire … for example: due to friction (bearings running hot, conveyor belt on jammed roller), electric motor burning out, thermostat failing, cooling system failure.  Explosion of the equipment … for example: due to pressure build-up caused by the failure of a pressure-relief valve or the unexpected blockage or sealing off of pipework.  Explosion of substances in the equipment … for example: due to exothermic chemical reaction or unplanned ignition of a flammable gas or vapour or finely divided organic material (such as flour or coal dust), or welding work on a container with flammable residues.

Question 10

The Approved Code of Practice to Regulation 7 (Specific Risks) of PUWER recommends that wherever possible, risks are always controlled by (in the order given):

Answer 10

 Eliminating the risks. OR if that is not possible  Taking ‘hardware’ (physical) measures to control the risks such as the provision of guards. But if the risks cannot be adequately controlled  Taking appropriate ‘software’ (management) measures to deal with the residual (remaining) risk, such as following safe systems of work and the provision of information, instruction and training.

Question 11

Under the Provision and Use of Work Equipment Regulations 1998 (PUWER) the employer has an absolute duty to

Answer 11

maintain work equipment in an efficient state, in efficient working order and in good repair. Here ‘efficient’ relates to how the condition of the equipment might affect health and safety and not productivity.

Question 12

These issues were considered to merit particular attention because of the severity of the harm that could be involved, and because they are commonly encountered during plant and building maintenance. 4

Answer 12

 disturbing asbestos  falls from height  falls of heavy items  inadequate isolations and permits to work.

Question 13

Maintenance programmes may be based on various maintenance methodologies. For the purpose of the NEBOSH Diploma the methodologies may be classified and characterised as: 3

Answer 13

 Breakdown.  Planned preventative.  Condition based.

Question 14

Designing an effective PPM programme for safety-critical machinery requires consideration of the following factors:

Answer 14

 The age and current condition of the machinery.  The nature of its usage – light or heavy duty.  Its breakdown history.  The operating environment (hazardous conditions – hot, dusty, corrosive).  Manufacturer’s recommendations for servicing.  Insurer’s requirements.  Statutory requirements under PUWER, LOLER, EAWR, etc.  The risks to health and safety of malfunction.  The timing of the intervention - the reliability of the schedule for servicing and replacement (the need for condition monitoring).  The effect failure would have on other components and on the process in general.  The availability of spare parts (procurement and storage considerations).  The need to minimise disruption to production (weekends or scheduled shut-downs).  An effective management system for flagging up the need for maintenance and logging maintenance activities.  The competence of the maintenance team / the need to contract in specialist support..

Question 15

Condition monitoring can be an effective tool for diagnosing the symptoms of impending equipment and machinery failures. It may include

Answer 15

sampling and analysis, vibration monitoring, operating parameter measurement, non-destructive testing techniques (NDT) and electrical testing procedures.

Question 16

Outline factors to be considered when developing a planned preventive maintenance programme for safety-critical machinery. 10 marks

Answer 16

Factors to be considered include:  the manufacturer’s recommendations and servicing and insurer’s requirements  the reliability of critical components using diagnostic techniques to predict failure, the effect failure would have on other components and on the process in general, and the need to plan their replacement before failure occurs which would require the storage of spare components  the risks to health and safety of malfunction  the age and current condition of the machinery and its usage, breakdown history and operating environment, whether in dusty areas, in high temperatures or in corrosive atmospheres. Additional factors to be considered would include:  the timing of the maintenance for example at weekends to prevent disruption to production  the methods to be used to identify maintenance periods such as the use of coloured tags and for recording the maintenance once completed  the competence of existing maintenance staff with the possibility that additional specialist training might be required. Reference to the requirements of relevant legislation, such as those contained in HASAWA, the Electricity at Work Regulations and PUWER, would also have gained marks here.

Question 17

Examples of inspections include: 3

Answer 17

 Quick checks before use, such as electric cable condition on hand-held power tools, functional testing of brakes, and lights on mobile machinery.  Weekly checks, such as presence of guarding, function of safety devices, tyre pressures, and the condition of windows, mirrors and CCTV on mobile plant.  More extensive examinations, undertaken every few months or longer, such as general condition of a ladder, close examination of a safety harness and portable appliance testing.

Question 18

The person who actually carries out the inspection should have sufficient knowledge of the equipment to: 3

Answer 18

 Enable them to know what to look at (know the key components).  Know what to look for (fault-finding).  Know what to do (reporting faults, making a record, who to report to).

Question 19

Functional testing of safety related parts Safety related parts might include: 3

Answer 19

 Guards and protective devices such as interlocked guards or light curtains (electro-sensitive protective equipment (ESPE) using active opto-electronic protection devices (AOPD)) which have to operate effectively to keep workers away from danger.  Brakes and lights on mobile work equipment such as forklift trucks.  Emergency stop controls on machinery.

Question 20

Records of equipment inspections do not have to be kept in a particular form, but should normally include: 9

Answer 20

(a) information on the type and model of equipment (b) any identification mark or number that it has (c) its normal location (d) the date that the inspection was carried out (e) who carried out the inspection (f) any faults (g) any action taken (h) to whom the faults have been reported (i) the date when repairs or other necessary action were carried out.

Question 21

If equipment has to run during a maintenance operation and this presents risks, appropriate controls should be introduced to reduce the risk, for example: 3

Answer 21

 provision of temporary guards  limited movement controls  crawl speed operated by hold-to-run controls.

Question 22

Regulation 9 of PUWER requires every employer to ensure that:  All persons who use work equipment have received adequate training for purposes of health and safety, including: 3

Answer 22

• training in the methods which may be adopted when using the work equipment - any risks which such use may entail - the precautions to be taken.

Question 23

What constitutes ‘adequate training’ will vary according to the job or activity and work equipment, etc. To ensure that training is adequate it will be necessary to: 3

Answer 23

 Evaluate the existing competence of employees to operate the full range of work equipment that they will use.  Evaluate the competence required to operate the full range of work equipment that they will use.  Train the employee to make up any shortfall between their competence and that required to carry out the work, with due regard to health and safety.

Question 24

List of items to be included in training programmes

Answer 24

 Equipment mechanisms, particularly their safety aspects  Guards and protection devices - types and functions of each type of guard or protection device, including closed tools where used, method of installation.  The causes and prevention of accidents  The work of the tool setter - safe methods of working, lubrication and co-operation with the press operator.  Tool design - in relation to safe systems of work.  How to carry out an inspection and test of the guard protection device or closed tool, including how to detect defects.

Question 25

Equipment with specific training needs 4

Answer 25

Chainsaws Power presses Woodworking machines Abrasive wheels

Question 26

Regulations 4 to 10 are the management duties of PUWER 98, covering selection of suitable equipment, maintenance, inspection, specific risks, information, instructions and training. It also covers the conformity of work equipment with legislation which brings into effect the requirements of EC Directives on product safety. List them

Answer 26

 Regulation 4: Suitability of work equipment  Regulation 5: Maintenance  Regulation 6: Inspection  Regulation 7: Specific risks  Regulation 8: Information and instructions  Regulation 9: Training  Regulation 10: Conformity with Community requirements

Question 27

Regulations 11 to 24 deal with the physical aspects of PUWER 98. They cover the guarding of dangerous parts of work equipment, the provision of appropriate stop and emergency stop controls, stability, suitable and sufficient lighting and suitable warning markings or devices. List them

Answer 27

 Regulation 11: Dangerous parts of machinery  Regulation 12: Protection against specified hazards  Regulation 13: High or very low temperature  Regulation 14: Controls for starting or making a significant change in operating conditions  Regulation 15: Stop controls  Regulation 16: Emergency stop controls  Regulation 17: Controls  Regulation 18: Control systems  Regulation 19: Isolation from sources of energy  Regulation 20: Stability  Regulation 21: Lighting  Regulation 22: Maintenance operations  Regulation 23: Markings  Regulation 24: Warnings

Question 28

Outline part 3 of PUWER

Answer 28

 Regulation 25: Employees carried on mobile work equipment  Regulation 26: Rolling over of mobile work equipment  Regulation 27: Overturning of fork-lift trucks  Regulation 28: Self-propelled work equipment  Regulation 29: Remote-controlled self-propelled work equipment  Regulation 30: Drive shafts

Question 29

Outline part 4 of PUWER

Answer 29

 Regulation 31: Power presses to which Part IV does not apply  Regulation 32: Thorough examination of power presses, guards and protection devices  Regulation 33: Inspection of guards and protection devices  Regulation 34: Reports  Regulation 35: Keeping of information