机械设备安全指南Guide to machinery and equipment safety

Guidetomachineryandequipmentsafety

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Introduction

Aguidetomachineryandequipmentsafetyisprovidedtoassistpersonsconductingabusinessorundertaking(PCBU)andworkerstocomplywiththeirdutiesunderthe

WorkHealthandSafetyAct2011(theAct)andtheWorkHealthandSafetyRegulation2011(theRegulation).

Thisguideisanintroductiontomanagingtherisksassociatedwithuseofmachineryandequipmentintheworkplace.

Relevantpersonscanusethisguideto:

•identifymachineryandequipmenthazardsintheworkplace

•eliminateorreducetheriskofthosehazardscausingharm.

Theguidewillalsobeusefultoanyoneelsewhoisinterestedinmachineryandequipmentsafety,suchasworkersandWorkplaceHealthandSafetyRepresentatives(WHSRs).

WorkplaceHealthandSafetyQueensland(WHSQ)alsohasadditionalinformationandguidancesupportingtopicsintroducedinthisdocument.Forfurtherinformation,refertoSection4.

Consultingworkersandworkplacehealthandsafetyrepresentatives

Consultativeprocessesallowpeopletoprovideinputandraisepotentialsafetyconcerns

abouttheworktheyundertake.Althoughhazardsassociatedwithmachineryandequipmentareofteneasilyidentified,thewaysinwhichpeoplecangainaccessto,ormaybeexposedto,hazardsrequireadetailedunderstandingofhowtheydotheirjob.

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1.Keyprinciplesofmachineryandequipmentsafety

1.1Mechanicalhazards

Machineryandequipmenthavemovingparts.Theactionofmovingpartsmayhavesufficientforceinmotiontocauseinjurytopeople.

Whenassessingmachineryandequipmentforpossiblemechanicalhazards,consider:

•machineryandequipmentwithmovingpartsthatcanbereachedbypeople

•machineryandequipmentthatcanejectobjects(parts,components,productsorwasteitems)thatmaystrikeapersonwithsufficientforcetocauseharm

•machineryandequipmentwithmovingpartsthatcanreachpeople,suchasboomsormechanicalappendages(arms)

•mobilemachineryandequipment,suchasforklifts,palletjacks,earthmovingequipment,operatedinareaswherepeoplemaygainaccess.

Commonmechanicalhazardsandassociatedrisksformachineryandequipmentareshownbelow.

Hazard

Risk

Rotatingshafts,pullies,sprocketsandgears

Entanglement

Hardsurfacesmovingtogether

Crushing

Scissororshearaction

Severing

Sharpedge–movingorstationary

Cuttingorpuncturing

Cableorhoseconnections

Slips,tripsandfalls(e.g.oilleaks)

Roboticarmscanreachovertheirbase,movewithremarkablespeedandhighforce,andcancauseinjuryifcontrolstoseparatepeoplefrommovingplantarenotimplemented.

Mobileplantoperatedinareaswherepeopleworkmaycauseinjurythroughcollision.Trafficcontroland

segregationareformsofcontrol.

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1.2Non-mechanicalhazards

Non-mechanicalhazardsassociatedwithmachineryandequipmentcanincludeharmfulemissions,containedfluidsorgasunderpressure,chemicalsandchemicalby-products,

electricityandnoise,allofwhichcancauseseriousinjuryifnotadequatelycontrolled.In

somecases,peopleexposedtothesehazardsmaynotshowsignsofinjuryorillnessforyears.Wherepeopleareatriskofinjuryduetoharmfulemissionsfrommachineryandequipment,theemissionsshouldbecontrolledattheirsource.

Whenassessingmachineryandequipmentforpossiblenon-mechanicalhazards,considerhowmachineryandequipmentcanaffectthearea(environment)aroundthem.

Commonnon-mechanicalhazardsareshownbelow.

Non-mechanicalhazards

Dust

Mist(vapoursorfumes)

Explosiveorflammableatmospheres

Noise

Heat(radiatedorconducted)

Ignitionsources(flameorspark)

Highintensitylight(laser,ultraviolet)

Moltenmaterials

Heavymetals(lead,cadmium,mercury)

Chemicals

Steam

Pressurisedfluidsandgases

Ionisingradiation(x-rays,microwaves)

Electrical

Woodworkingdustgeneratedbyabuzzeris

removedviaforcedextractionandventilation.

Weldingfumesareextractedviaflexible,locatableforcedextractionandventilationsystem.

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1.3Accesshazards

Peoplemustbeprovidedwithsafeaccessthatissuitablefortheworktheyperformin,onandaroundmachineryandequipment.Astableworkplatform,suitedtothenatureofthework

thatallowsforgoodposturerelativetotheworkperformed,surefooting,safeenvironmentandfallprevention(ifafallmayoccur),isabasicrequirement.Forexample,coolingtowersonbuildingroofsmayhavepooraccess,yetmustbeattendedbyaservicepersonat

predictabletimesforwatertreatment,chemicaldosingormonitoringofautomateddosing

equipment.Peopleperformingthesetasksmustbeprovidedwiththemeanstogetthemselvesandanyequipmenttheyrequireontotheroofwithnorisk,orminimalriskoffallorinjury.

Whenthinkingaboutsafeaccesstomachineryandequipment,considerthefollowing:

•whowillbeworkingonoraroundthemachineryandequipment

•peoplewhoarerequiredtoworkinenclosedareaswheretheatmospherecouldbeharmful,suchaspits,tanksorstoragevessels

•whatequipmentormaterialsneedtobecarriedtoundertakethetask

•whereandwhenisaccessrequiredforoperation,maintenanceandcleaning

•howwillpeoplegainsafeaccess(walkway,gantry,elevatedworkplatformorladder)

•whatworkwillbecarriedoutduringaccess

•willpeoplebenearorexposedtoanunidentifiedmechanicalornon-mechanicalhazardatthetimeofaccess

•hasconsultationoccurredwithworkersorcontractorsregardinghowtheyintendtogainaccess,andwhatequipmentandworkplatformorstructureisbestsuitedfortheintendedtask.

Access

Accessneedscanbepredictedandplanningmustoccurinadvance.Peopleneedaccessto

machineryandequipmentintheworkplace(eithercontinuallyoroccasionally)forpredictabletaskssuchasoperation,maintenance,repair,installation,serviceorcleaning.Accessmay

varyduringeachstageofthemachineryandequipmentlifecycle.Forexample:

•installationorremoval

ocompleteaccessfromeveryareamayberequiredandinvolvedisconnectionorconnectionofservices,suchaswater,air,pipes,installationofelectricalcabletoswitchboard

•operation

oaccessforsetup,operationandadjustment

•maintenance,repair,cleaning,alterationoradaptation

oaccesstoremoteareasmayberequired.

Permanentlyfixedgantries,laddersandwalkwaysareincorporatedintothismachineryand

equipmenttoreducetheriskofafallfromheightoccurringduringoperationandmaintenance.

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Followingareexamplesofcommonhazardsbytypeofworkplaceactivity.

Peoplewhoinstallordismantlemachineryandequipmentcould:

•workinisolation

•workonmachineryandequipmentatheight,orovermachineryandequipmenttoconnectservices,suchaselectricity,airorwater

•workinlowlight,orwithbrightdirectionallight

•accessmachineryandequipmentfromthetop,sidesorunderneath

•workwithornearcranes,forkliftsorriggingtoliftmachineryandequipment

•workinconfinedspaces

•usepowertools,welders,extensionleads,whichpresentelectricalhazardsifdamagedorwet.

Peopleoperatingmachineryandequipmentcould:

•berequiredtoplacetheirhandsclosetothemechanismofthemachineryandequipmentthatdoesthework,andmaybeinjuredifcaughtortrappedbymovingparts

•beexposedtoconstantharmfulnoise,radiatedenergyorfumesbeingemittedfromthemachineryandequipmentbeingoperated,orarecloseto

•inadvertentlybumporknockpoorlyplacedcontrolleversorbuttons

•berequiredtomakeadjustmentstothemechanismofmachineryandequipmentwhilethemachineisinmotion

•berequiredtoclearawayscrap

•makeminoradjustments,orreachintothemovingmechanismofthemachineryandequipmentbeingoperated.

Peopleprovidingmaintenanceorrepairservicescould:

•workalone

•workonmachineryandequipmentatheight,orovermachineryandequipmenttoconnectservices,suchaselectricity,airorwater

•accessmachineryandequipmentfromtherearorsides

•berequiredtoenterconfinedspacesoflargermachineryandequipment

•betrappedbythemechanismofthemachineryandequipmentthroughpoorisolationofenergysourcesorstoredenergy,suchasspring-loadedorcounter-balancemechanisms,compressedairorfluids,orpartsheldinpositionbyhydraulicsorpneumatic(air)rams

•moveheavypartswhenchangingthesetupofmachineryandequipment,orrepairingfailedparts,suchaselectricmotorsorgearboxassemblies

•disableorremovenormalsafetysystemstoaccessthemechanismofmachineryandequipment.

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Peopleprovidingcleaningservicescould:

•workalone

•accessmachineryandequipmentfromtherearorsides,orinunexpectedways

•climbonmachineryandequipment

•enterconfinedspaces,orlargermachineryandequipment

•becometrappedbythemechanismofthemachineryandequipmentthroughpoor

isolationofenergysourcesorstoredenergy,suchasspring-loadedorcounter-balancemechanisms,compressedairorfluids,orpartsheldinpositionbyhydraulicsor

pneumatic(air)rams

•workwithchemicals

•operateelectricalequipmentinwetareas.

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2.Riskcontrolofmachineryandequipmenthazards

2.1Riskcontrolofgeneralhazards

Whereexposuretomachineryandequipmenthazardscannotbeeliminatedorsubstitutedfor

machineryandequipmentofimproveddesign,riskcontrolsmustbeappliedtothehazardstopreventorreducetherisk(chance)ofinjuryorharm.Workplacehealthandsafetylaws

requirethehighestordercontrolbeapplied.

Higherordermachineryandequipmentriskcontrolsarepreventativebynature,areeffectiveanddurablefortheenvironmentitisusedin,anddealdirectlywiththehazardatitssource.

Lowerordermachineryandequipmentriskcontrols,suchaspersonalprotectiveequipment(PPE),canpreventinjuries,butaregenerallynotaseffectiveashigherordercontrols,astheyrelymoreonworkerbehaviour,maintenanceprogramsandsupervision.

Administrativecontrolsusesystemsofworktoreduceriskbyprovidingaframeworkofexpectedbehaviours.Examplesarerotationofstafftoreduceexposuretoahazard,ora

documentedsafesystemofwork,suchas‘lockouttagout’.Thesetypesofcontrolsrelyonextensiveinstruction,information,trainingandsupervision.Intermsoftimeandongoingadministrationbymanagersandemployerstoensurethedesiredbehaviouroccurs,

administrativecontrolscanbethemostexpensiveandleasteffectiveformofhazardcontrol.

Note:TheuseofPPEandadministrativecontrolsareloworlastordercontrolsusedtodealwithanyresidualriskassociatedwiththehazard.Assuch,theselastordercontrolscanbeusedinsupportofhigherordercontrolsthatdealwithahazardatitssourceandshouldnotbeconsideredasthesolemeansofcontrol.Thesetypesofriskcontrolsrequireconstantmonitoringandreinforcement.

Effectivemachineryandequipmentriskcontrolsreflectsomeorallofthefollowingcharacteristics:

•thehazardiscontrolledatitssource

•contactoraccesstothehazardisprevented

•sturdyconstruction(correctmaterialswithfewpointsofpotentialfailure)

•fail-safe(failureofthecontrolsystemtobeeffectivewillresultinmachineryshut-down)

•tamper-proofdesign(asdifficultaspossibletobypass)

•presentsminimumimpedimenttomachineryandequipmentoperator

•easytoinspectandmaintain

•doesnotintroducefurtherhazardsthroughtheriskcontrolaction.

Centrelathe:Theexposedrotatingchuckofa

centrelathecanejectpartsortoolswithgreatforce,cuttingfluidfumesaredifficulttocontainandthemachineryrequiresmanualset-up.

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CNClathe:SubstitutingacentrelathewithaCNClathe(ComputerNumericControl)isanexampleofimprovedriskcontrolofmachineryandequipmentthroughimprovementindesign.

2.2Riskcontrolofmechanicalhazards

Separationisasimpleandeffectivemachineryandequipmentriskcontrolandmaybeachievedbydistance,barrierortime.

•Distanceseparationmeansapersoncannotreachthehazardduetodistance.

•Barrierseparationmeansaneffectivebarrierorguarddeniesaccessandcontrolsejectionofparts,productsorwaste.

•Timeseparationmeansatthetimeofaccess,themachineryand/orequipmentisdisabled.

Examplesofseparationinclude:

•physicalbarriersandguards,suchasfences,screensorfixedpanelsofvariousmaterials

•variousformsofguardingandinterlocking(asdescribedinAS4024,parts1601and1602,SafetyofMachinery)

•makingthehazardinaccessiblebyreach(wherethedistancebetweenapersonandthehazardformsaneffectivebarrier).

Note:Whenconsideringthesuitabilityofdistanceguarding,considerthesafeaccess

requirementsofmaintenancepeoplewhogainaccessbyladder,scaffoldorelevatedworkplatform.

Guarding

Aguardcanperformseveralfunctionsincluding:

•denyingbodilyaccess

•containingejectedparts,tools,off-cutsorswath

•preventingemissionsescaping

•formingpartofasafeworkingplatform.

Guardingiscommonlyusedwithmachineryandequipmenttopreventaccessto:

•rotatingenddrumsofbeltconveyors

•movingaugersofaugerconveyors

•rotatingshafts

•movingpartsthatdonotrequireregularadjustment

•machinetransmissions,suchaspulleyandbeltdrives,chaindrives,exposeddrivegears

•anydangerousmovingparts,machineryandequipment.

Whereaccessisnotanticipated,afixedguardcanbepermanentlyappliedbyabondingagent,welding,orsecuredwithone-wayscrews.Ifaccessisgenerallynotrequired,a

permanentlyfixedbarrieristhepreferredoption.

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Whereaccesstothehazardisinfrequent,theinstallationofafittedguard,thatcanbe

removedbyuseofatool,maybeanacceptablecontrol,wherethetooltoremovethebarrierorguardisnotnormallyavailabletotheoperator.

Adjustableguardingincorporatesmovablesectionsorpanelsoftheguardandallowsformaterialorpartstobefedintotheguardedareawhilestillpreventingbodilycontact.

Anoldstylepowerpressincorporatingamanualinterlockandadjustableguarding.

Iftheguardslidesup,aconnectedmetalbar

separatestheclutchmechanismandthepresswill

notactivate.Theguardcanbeadjustedtoprovideanopeningbyreleasingretainingboltsontheguard

facetoallowindividualpanelstomove.

Adjustmentmustbeperformedbyanexperienced

persontoensuretheresultingopeningonlyprovidesroomnecessarytoincorporatethematerialbeingfedinandpreventshandsorfingersintrudingintothe

dangerarea.

Fences,barriers,guardsandinterlockedgatesseparatepeoplefromthehazardousactionofmachineryand

equipment.

Tunnelguardsprovideatunnel,apertureorchuteinwhichmaterialcanbeinsertedintothemachineryandequipment,butduetotherestrictivedesignanddepthoftheopening,fingers,hands,arms,ortheentirepersonispreventedfromintrudingintothedangerarea.

Wherefrequentcleaningisrequired,theguardmaybeconstructedofmeshthatprevents

intrusionofbodyparts,butallowsforhosing.Foodproductionworkplaces,thatuseconveyorsinareaswherehygieneorfoodsafetyisanintegralpartoftheoperation,usefixedmesh

guardingofconveyorendrollers.

Interlockguardingoccurswhentheactofmovingtheguard(opening,slidingorremoving)toallowaccess,stopstheactionofthehazardousmechanism.

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Interlockguardingworksby:

•disconnectingthedrivemechanismmechanically(e.g.applyingabrakeordisengagingaclutchorgearedmechanism)

•isolatingthepowersourceofthedrivemechanism(e.g.stoppingthemotor)

•acombinationofmechanicalandpowerdisconnection.

Interlockguardingisgenerallyachievedviamechanicalorelectricalmeans,butmayalsoincludehydraulicorpneumaticcontrolsystems.

Theenergystoredinmovingparts(momentum)cancausethemechanismofthemachineryorequipmenttorunonforsometimeafterthesourceofdrivingenergyhasbeenremoved.

Foraccesspanelsordoorssupportinganinterlockingdeviceallowingaccesstomechanicalpartsthatmoveforperiodsaftertheenergysourceisremoved,aseparatemechanismto

delayreleaseoftheretainingorlockingmechanismmaybeincorporated.

Captivekeysystemsrelyuponasinglekeythatissharedbetweenthecontrolpanel(‘on’switch)andtheaccessgatelockofthephysicalbarriertothedangerarea.Removalofthekeyfromthecontrolpanelcanonlyoccurwhentheswitchisinthe‘off’position,andthegatewillonlyreleasethekeywheninthelockedposition.

Captivekeysystemsdonotprovidefullisolationofthepowersource,butmayprovidelimitedtemporaryaccessundercontrolledconditions.

Administrativecontrols,suchaseffectivesupervision,instructionandtraining,arerequiredtoensurethatonlyonekeyisavailableforthesystem,andthekeyisnotremovedfromtheaccessgateorguardbyasecondoperatorwhileapersonisexposedtothedangerareaoftheplant.Operationssuchasmaintenance,repair,installationserviceorcleaningmayrequireallenergysourcestobeisolatedandlockedouttoavoidaccidentalstart-up.

Thenarrowthroatofthemincerpreventsaperson’shandfromaccessingthehazard.

Captivekeysystems:Thekeycannotberemovedunlessitisintheoffposition.Thesamekeyisusedtounlocktheaccessgate.Onlyonekeypersystemisretainedbythelockingmechanism.

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Anoldstylepressrefurbishedwithaninterlockedsafetycageandgate.

Thecontrolmechanismusesacombinationofpneumaticsand

electricalinterlockingtoensurethedangerareaofthepress

cannotbeaccessedunlessthepressdownstrokeactionisdisabled.Improveddesignandtechnologycanbefittedtooldermachineryandequipmenttomeetcurrentstandardsandreflectthelatest

knowledgeregardingwaystocontrolhazardsandrisksintheworkplace.

Othermechanicalhazardriskcontroloptions

Simultaneoustwo-handedoperation

Whereamachinehasonlyoneoperator,theuseofsimultaneoustwo-handedoperation

buttonscanserveasariskcontrol.Thisensuresthatoperationofthehazardousmechanismcannotoccuruntilbothhandsareclearofthedangerarea.

Thetwobuttonsmustbepushedatthesametimeandarelocatedatadistancefromeachotherthatpreventssimultaneousoperationbyonehand.

Theoperationshouldbedesignedsothatifeitherorbothofthebuttonsarereleased,thehazardousactionofthemachineryand/orequipmentcannotbereached,orifitcanbe

reached,themechanismreturnstoasafestate.

Presencesensingsystems

Ifphysicalguardscannotbeused,thenapresencesensingsystemcanbeusedasacontrolto

reducerisk.Presencesensingsystemscanbeusedwherepeopleenterareassharedbymovingproductionequipment.

Presencesensingsystemsarecapableofprovidingahighdegreeofflexibilitywithregardtoaccess.

Presencesensingsystemsdetectwhenapersonisintheidentifieddangerarea,andstopsorreducesthepowerorspeedofthemechanismatthetimeofentrytoprovideforsafeaccess.

Presencesensingsystemscanrelyonfootpressurepads,infra-redsensing,lightbeamsorlaserscanning.Themostappropriatetypeofsensingdevicewilldependontheoperatingenvironmentandaccessrequirements.

AS4024.2providesguidanceondesignspecification,ratingsonintegrityandreactiontimes.Manufacturers’specificationsforinstallationandmaintenancemustalsobeobserved.

Specialistassistancemayberequiredbyexperiencedprofessionalstoensurethecorrectselectionandinstallationofpresencesensingsystems.Companieswhomanufactureorsupplythesesystemsalsoprovidetechnicalsupportandinstallationassistance.

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Atwo-handedcontroloptionmaybesuitabletoensurethatamachinecannotoperateuntilbothhandsoftheoperatorareclearofthehazardarea.

Alightcurtainusedtodisablethehazardous

mechanismofamachinemustresistfailureandfault.

Criticalsafetysystems

Acriticalsafetysystemisasafetycontrolsystemresponsibleforensuringthesafetyofapersonwhenapproachingoraccessingahazard.

Failureofthecriticalsafetysystemwillleaveapersonexposedtothehazard,andindanger.

Criticalsafetysystemsmayincludebarriersorguardsfittedtopreventaccess,orintegratedcomplexinterlockingandpresencesensingsystems.Failuretoreplaceguards,damaged

perimeterfencesthatallowaccess,andbypassedordisabledinterlockingsystems,are

examplesofcriticalsafetysystemsfailuresthatrequireimmediateattentiontoensurethesafetyofpeople.

Highintegrity/fail-safecontrol

Allsafetycontrolsystemsshouldbedesignedandbuilttopreventfailureor,intheeventoffailure,de-activatetheoperationofthemachineryandequipment.

Theextenttowhichasafetycontrolsystemshouldtoleratefaultsisafunctionofrisk

(likelihoodandconsequence),andisdescribedfullyinAS4024.1501SafetyRelatedPartsofControlSystems,whichexplainsthecategoriesofcontrolrequiredasafunctionofincreasingrisk.

Manydifferenttypesofmachineryandequipmentusehighintegritysafetysystemsthatdisableamechanismatthetimeofaccess.Someexamplesinclude:

•brakepress

•powerpress

•roboticmachine(automatedmachines)

•injectionmoulders

•poweredguillotines

•programmablelatheandmillingequipment

•industrialmixers

•mincingequipment

•plasmacuttingtables

•lasercuttingtables.

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Redundantandself-monitoringfaultdetectionsystems

Redundantordualsystems(doublingup)andself-monitoringfaultdetectionsystemsarealsoeffectivemethodstopreventfailureofcriticalsafetysystems.

Selectionandinstallationofthesetypesofcomplexinteractivecontrolmeasuresmayrequireexpertorspecialistassistance.

TheAustralianStandardsprovideinformationonmachineryandequipmentsafetysystems

andreflectthecurrentstateofknowledgeandbestpractice.TheAS4024SafetyofMachineryseriesofpublicationsprovidesspecificinformationforcommonlyusedmachinetypesin

industry,suchaswoodworkingormetalworkingmachinery.

Componentsreliedontoprotectpeoplefromharmaredesignedandbuilttoahighstandard,anddisplay

complianceratingsrelativetotheirreliability.They

mustalsobecorrectlyinstalledtoensuretheireffectiveoperation.

2.3Riskcontrolofnon-mechanicalhazards

Thefirststepinselectingsuitableandeffectivecontrolsfornon-mechanicalhazardsistounderstandthenatureofemissionsthatcanbereleasedbymachineryandequipmentintheworkplace,wherethoseemissionscollectandthewaytheymaycauseharm.

•Separatingpeoplefromnon-mechanicalhazardsisnecessarywheretheemissioncannotbecontrolledatthesourcethrougheliminationorsubstitution.Hazardousmachineryand

equipmentemissioncontrolsrelylargelyonisolatingofpeoplefromthehazardous

emission.Hoods,lids,coversorimperviousguards(solidbarriersthatpreventescapeoftheemission)canservetocontainanumberofdifferenttypesofemissionswithinmachinery

and/orequipment.Forpotentiallyharmfulsubstanceexposuresfrommachineryand

equipment,suchasmist,fumes,vapourordust,andwhereitisnotpossibletocontroltheemissionatitssource,ventilationandextractionsystemsareusedtoremovethehazardousemissionsfromtheworkenvironment.

•Guardingmayalsoservetomutenoiseemissionsthroughapplicationofsoundabsorbingmaterials.Otheremissions,suchaslasers,ultravioletlight,brightlightorweldingflash,canalsobesafelyscreenedtopreventpotentialharmfulexposure.

•Oilleaksfrommachineryand/orequipmentmaypresentaserioussliphazard.Bypreventingoilleaksthroughroutinemaintenance,orcontainingleakingoilwithadriptrayorthroughspillcontainmentstrategies,theriskthehazardpresentsiscontrolled.

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Personalprotectiveequipment

Whereitisnotpossibleforemissionstobecontrolledattheirsource,orremovedorreducedthrougheffectiveventilation,extractionordiversion,theuseofpersonalprotectiveequipment(PPE)asafinalmeasuremustbeconsideredtoensuresafety.

PPEisalowerordercontrolandcanonlybeusedwherehigherordercontrolsarenotpossibleorarenottotallyeffective.

SelectionanduseofPPErequirescarefulconsideration,astherearemanydifferenttypesthatreducetheriskofinjuryofcontactorexposuretoahazard.

IncorrectuseofPPE,orpurchasin