PLANT/EQUIPMENT/ASSET HAZARD REPORT

Size: px

Start display at page:

Download "PLANT/EQUIPMENT/ASSET HAZARD REPORT"

Jocelyn Stanley
5 years ago
Views:

1 Asset Description: EL Overhead Transfer System and EMS. Sale Type For what use is this asset being sold? Re-Use Spare Parts Scrap Note 1: Assets are sold only for the use indicated. Any other use is at the buyer/recipient s own risk. Inspection Date: 2/12/2017 Asset Location: Plant 2 Body Shop LOT Number(s): 4002 Serial Number: Make: Webb, JLT, Daifuku Model: Maintenance Records Available? (Y/N) No Audited By: Jason Wood, Hayden Barr Operations Manual Available? (Y/N) No Hazard Category: Item Hazard Applicable (Y/N) Item Hazard Applicable (Y/N) Item Hazard Applicable (Y/N) 1 Y 10 Slips, Trips and Falls Y 19 Failure of Power Supply 2 Y 11 Ergonomics Y 20 3 Thermal 12 Working at Heights Y 21 4 Noise Y 13 Mobile Plant and/or Traffic Management Servicing, Maintenance, Inspection and Monitoring Regulatory licensing, registration, plates and or labelling 22 Environmental 5 Vibration 14 Hydraulic Hazards 23 Training Y 6 Chemical (Hazardous Substances and/or Dangerous Goods) 15 Pneumatic, Vacuum and Pressure Hazards 7 Radiation 16 Manual Handling Y 25 Exposure Hazards 24 Signage Y 8 Confined Spaces 17 Personal Protective Equipment Y 26 Emergency Management Asbestos and/or Hazardous 9 Materials Comments: 18 Loss of Stability/Overturning Y 27 (other) Y Y Page 1 of 8

2 Note 2: This plant information has been prepared to assist the purchaser in identifying hazards associated with the plant prior to the purchaser dismantling, transporting and commissioning plant for their own intended purposes. It is recommended that the purchaser of this plant conducts a hazard identification and risk assessment and refers to the attached information which has been provided to assist the purchaser in ensuring that the plant is safe (i.e. make the necessary modifications or otherwise eliminate or control so far as practicable all risks associated with the use of the plant) and only used for the purposes for which the plant was originally designed. Note 3: Each hazard assessment is based on a visual inspection only and, in some cases, observing the asset in operation in the manner that the asset was used by the seller. Unless otherwise specified, no other testing has been carried out on or in relation to the asset (e.g. stress, noise, vibration, braking efficiency, insulation, load, crack testing etc.). Consequently, this report outlines known hazards/risks for this Asset and, whilst reasonable efforts have been made to identify hazards/risks, some hazards/risks may not have been identified nor appropriate conditions detailed in this report. The buyer/recipient is responsible for conducting its own inspection and assessment of the asset prior to its sale/receipt, transport or use, and appropriately managing any hazards/risks (whether expressly identified herein or not) prior to transport or use of the asset. The conditions outlined in this report do not account for hazards/risks associated with the decommissioning, transportation, and reinstallation and new operating conditions of the asset once removed from the seller s site. Note 4: The conditions below offer one approach to managing the hazards/risks associated with using the asset in the manner it was used by the seller. Other approaches may be acceptable, subject to advice from a suitably qualified professional. The buyer is required to conduct its own assessment to identify and appropriately manage any other hazards/risks before transporting or using this asset. Category Hazard Description Recommended Controls ENTANGLEMENT hazards associated with clothing, jewellery, body parts, hand held objects in rotating parts, projections or gaps in moving machine, between rotating and fixed parts, and materials in motion. CUTTING hazards associated with sharp edges, sharp materials being processed, sharp edges of plant if person slips, falls or strikes edge quickly CRUSHING hazards associated with moving parts of machine, and fixed structures, materials falling, plant falling, material moving on plant, machine and materials being processed. Page 2 of 8 Ensure entanglement hazards are eliminated or controlled by installing guards where possible in accordance with AS 4024 Safety Guarding of Machinery (or equivalent International Standard). Fixed guards should only be removable with a tool or key, solid and sturdy, permit routine adjustment/lubrication without removal where possible, shall not create hazard with sharp edges or trap points In addition, fixed guards shall not inhibit compliance with food hygiene requirements, openings, and distance guards, shall comply with reach distance detailed in AS 4024 Safety Guarding of Machinery (or equivalent International Standard) as well as other requirements associated with interlocking. Ensure cutting hazards associated with asset are assessed when installed (considering during testing, inspection, maintenance, cleaning or repair) and the appropriate risk controls implemented to reduce the risk and/or minimise altogether. Controls shall consider the hierarchy of controls including elimination of hazards, engineering controls and personal protective equipment (PPE) Ensure crushing hazards are eliminated by installing appropriate controls including but not limited to guarding, ensuring goods are secure, all elements of the plant are contained and not exposed. Fixed guards should only be removable with a tool or key, solid and sturdy, permit routine adjustment/lubrication without removal where possible, shall not create hazard with sharp edges or trap

3 SHEARING hazards associated with moving parts of plant or between machinery part and a work piece FRICTION hazards associated with abrasive moving parts and/or fast moving surfaces Potential energy release hazards exist associated with parts including but not limited to springs, tension shafts, counterweights, objects held under hydraulic/gas pressured by electro-magnetic devices. AMPUTATION hazards associated with moving parts of plant or between machinery part and a work piece Shock hazards associated with contact with electricity, including unprotected live circuits, unlocked electrical cabinets, inadequate space surrounding conductor, damaged or defective conductors, overloaded circuits, water or combustible medium contacting live conductors. Page 3 of 8 points In addition, fixed guards shall not inhibit compliance with food hygiene requirements, openings, and distance guards, shall comply with reach distance detailed in AS 4024 Safety Guarding of Machinery (or equivalent International Standard) as well as other requirements associated with interlocking. Ensure shearing hazards are risk assessed and the appropriate risk controls are implemented to reduce the risk or eliminated altogether. Controls shall consider the hierarchy of controls including elimination of hazards, engineering controls and personal protective equipment (PPE) Ensure Friction hazards are risk assessed and the appropriate risk controls are implemented to reduce the risk or eliminated altogether. Controls shall consider the hierarchy of controls including elimination of hazards, engineering controls and personal protective equipment (PPE) Ensure all hazards associated with potential energy release are risk assessed and the appropriate risk controls are implemented to reduce the risk or eliminated altogether. Controls shall consider the hierarchy of controls including elimination of hazards, engineering controls and personal protective equipment (PPE) Ensure amputation hazards are risk assessed and the appropriate risk controls are implemented to reduce the risk or eliminated altogether. Controls shall consider the hierarchy of controls including elimination of hazards, engineering controls and personal protective equipment (PPE) Undertake an assessment of the asset/equipment to ensure all electrical risks are managed including but not limited to ensuring all electrical leads, circuits, conductors and wiring is safe and conforms to AS/NZS 3000: installations, AS Safety of machinery equipment of machines or an international equivalent standard. Ensure all staff that work on electrical equipment are appropriately trained and qualified. Ensure the appropriate safety switches are in place (Earth Leakage

4 Shock hazards associated with improper grounding shocks and explosion hazards associated with high voltage installation work associated with asset. Shock hazards associated with exposed electrical parts Shock hazards as a result of liquids coming into contact with electrical components of the asset Shock as a result of not applying proper safety precautions Burn, noise and explosion related hazards associated with Arc Flash Protection) and that the appropriate processes are in place associated with live testing, maintenance and testing of equipment and Personal Protective Equipment (PPE) is worn as required. Ensure the installation of asset includes appropriately grounding in accordance with AS/NZS 3000: installations, AS Safety of machinery equipment of machines or an international equivalent standard. All HV work to be undertaken by appropriately qualified and experienced HV electrician or electrical engineer. Ensure HV connect/disconnect processes are in place and that the appropriate regulatory reporting processes are followed with regards to HV work. Ensure an assessment of the electrical component of the asset/equipment is undertaken and all wires and panels have no exposed parts and all openings are closed, outer insulation of materials are intact and the appropriately rated cords/wiring is in place in accordance with AS/NZS 3000: installations, AS Safety of machinery equipment of machines or an international equivalent standard. Undertake an assessment of the physical environment surrounding the use of the asset and ensure there risks associated with water coming into contact with the asset are eliminated. Ensure only appropriately trained and qualified staff undertake electrical work and ensure the following safety precautions/equipment are followed/used: - Personal protective equipment (PPE) - Inspect tools - Ground fault circuit interrupters (GFCIs) - Lock-out/tag-out Ensure a risk assessment of the equipment is undertaken associated with the potential for Arc Flash events and ensure the appropriate risk controls are implemented in line with AS/NZS 3000: installations, AS Safety of machinery Page 4 of 8

5 Noise Slips, trips and falls Ergonomics Working at Heights inspection of asset/equipment not maintained in accordance with AS/NZS 3760: In Service Safety Inspection and Testing of Equipment Circuits, Cabling, Conductor sizing and/or safety circuits may not comply with current standards An emergency stop device switch is not in place The use of this equipment/asset generates high levels of noise which can result in exposure to noise levels in excess of regulatory requirements. Slips, trips and falls hazards apply to the use of this asset/equipment Ergonomic hazards associated with potential for poor workplace design, awkward body mechanics or posture, repetitive movement and forceful motion and other ergonomic hazards may induce operator sprains and strains. The asset/equipment does not have any walkways and access to areas above 2 metres from the ground equipment of machines or an international equivalent standard. Ensure inspection and testing of asset/equipment occurs in accordance with AS/NZS 3760: In Service Safety Inspection and Testing of Equipment or equivalent International Standard prior to use to ensure safe operation of the equipment Undertake an assessment of the asset/equipment to ensure all electrical risks are managed including but not limited to ensuring all electrical leads, circuits, conductors and wiring are safe and conform to AS/NZS 3000: installations, AS Safety of machinery equipment of machines or an international equivalent standard. Install an emergency stop device which conforms to AS Safeguarding of Machinery and AS Equipment of Industrial Machines or equivalent international standards Undertake a review of the equipment/asset and if possible implement controls to reduce the generation of noise emissions. In addition, hearing protection should be provided to those working with this equipment/asset or working nearby. Ensure compliance with local regulatory noise exposure requirements. Ensure a detailed risk assessment is undertaken of this asset/equipment associated with slips, trips and falls and ensure all risks are eliminated or controlled in line with the hierarchy of controls Undertake an ergonomic assessment of the asset/equipment and ensure all identified risks are eliminate or managed appropriately to reduce the risks associated with ergonomic hazards. Ensure access to the upper areas of the asset/equipment is improved by installing fixed platform and ladders or restrict access to the area. Access platforms and ladders should conform to AS Fixed Page 5 of 8

6 Working at Heights Working at Heights Working at Heights Pneumatic, Vacuum and Pressure Pneumatic, Vacuum and Pressure Pneumatic, Vacuum and Pressure Manual handling Fixed platform and walkways are less than 600 mm in width which presents a potential hazard associated with falls from heights Platforms and walkways associated with this asset/equipment is of an open mesh style and does not have kickboards to prevent objects from falling from upper levels Fixed ladder(s) associated with asset/equipment is in excess of 2.4 metres and does not have a cage or fall arrest device which creates a falls from heights hazard Failure of flexible hoses resulting in uncontrolled release of air and pressure with the potential to result in injury Working on pneumatic systems under pressure can result in uncontrolled release of pressure with the potential to result in injury Pneumatic hoses and fittings may not be located and shielded to protect the operator from injury due to uncontrolled air release or movement of the hose as a result of leakage or components failure. Processes associated with the use of this equipment/asset/plant may result in hazardous manual handling including but not limited to the application of repetitive force, sustained force, high or sudden force, awkward posture and repetitive movement. Page 6 of 8 platforms, walkways, stairways and ladders - Design, construction and installation or an equivalent international standard. Assess the risk associated with the narrow platform and walkway and if the risks are high, widen the fixed platform and walkway in accordance with AS Fixed platforms, walkways, stairways and ladders - Design, construction and installation or an equivalent international standard. Ensure all platforms and walkways have the appropriate kickboards in accordance with AS Fixed platforms, walkways, stairways and ladders - Design, construction and installation or an equivalent international standard. Use of tool lanyards is recommended whilst working over open mesh flooring/ underguarding. Ensure all fixed ladders to asset above 2.4 metres has a cage in accordance with AS Fixed platforms, walkways, stairways and ladders - Design, construction and installation or an equivalent international standard. Undertake an inspection of all flexible hoses associated with asset/plant and ensure faulty or worn hoses are replaced prior to operating the asset/equipment. Ensure that all pressure is released prior to performing maintenance or de-commissioning tasks. Ensure operators are trained on the correct method of working on pneumatic systems and ensure the appropriate procedures and processes are in place. Undertake an inspection of all pneumatic hoses and ensure that the operator is either shielded or away from any possible fluid jet from the hose due to leakage. Ensure manual handling risk assessments are undertaken associated with the use of this asset/equipment/plant and ensure the appropriate risk controls are implemented prior to using the equipment.

7 PPE Loss of stability/overturnin g Service, maintenance, inspection & monitoring Service, maintenance, inspection & monitoring Training Signage Signage Signage The use of this equipment/asset/plant item without the appropriate personal protection equipment (PPE) may result in an injury to the operator. This asset/equipment/plant item may become unstable if not securely mounted /fixed as per manufacturers guidelines No maintenance, service, inspection or monitoring records available. No daily operational safety check and/or logbook available Operating this machine without the appropriate skills, training and competency is not safe Operator injury may result from illegible or missing warning labels/signage (noise, PPE, operating instructions, hot surfaces, exits, rotating fans, nip points etc.). Emergency stops are not clearly labelled Isolation switches are not clearly labelled Identify type of PPE required to be worn associated with the use of this equipment/asset/plant item and provide instruction/information regarding the use, storage, care and maintenance of PPE (e.g. eye & hear protection, dust mask etc.) Ensure asset/equipment/plant item is set up appropriately and in line with manufacturer specifications so that the equipment is securely fixed/mounted and or restrained/supported. Ensure the appropriate maintenance, inspection and monitoring of the asset/plant/equipment is undertaken in accordance with the manufacturer's and designer's requirements. Ensure the appropriate facilities and systems of work are in place to ensure the safety of persons who perform the maintenance, inspection and cleaning. If access to the plant is required to perform these tasks, the plant must be stopped and one or more of the following measures must be used to control the risks, lockout or isolation devices, danger tags, permit to work systems or other control measures. Ensure that a logbook is completed with daily operational safety checks and records of faults, repairs and maintenance. Ensure logbook is retained with plant/equipment. Ensure only suitably qualified, experience and competent operators use this machine/equipment. Ensure signage is installed and compliant with AS 1319 safety signage for the occupational environment or an equivalent international standard (for overseas buyers) Ensure emergency stops are clearly labelled in accordance with AS Safeguarding of Machinery and AS Equipment of Industrial Machines or equivalent international standards Ensure isolation switches are clearly labelled in accordance with AS Safeguarding of Machinery and AS Equipment of Industrial Machines or equivalent international standards Page 7 of 8

8 Signage There are limited operator controls labels in place so the operator is aware of specific controls associated with this equipment/asset. Plant failure may result from insufficiently or incorrectly maintained (inspection and adjustment) controls, settings or other key operational components Operational controls are not all easily identifiable Operational failure hazards exist associated with hoists and winches which could result in failure of equipment and/or collapsing of load Operational failure hazards exist associated with lifting devices, chains and slings which could result in failure of equipment and/or collapsing of load Operating the equipment/plant without the appropriate controlled work area is not safe. Ensure the appropriate operator controls labels are in place in line with manufacturer's specifications. Ensure all controls, setting and operational controls are set up properly before operating this plant/asset. Undertake an assessment of the asset/plant against manufacturer specifications and ensure all operational controls are clearly identified and labelled. Ensure that hoist is commissioned as per as AS cranes hoists and winches and AS cranes hoists and winches - crane runways and monorails and AS : cranes, hoists and winches - safe use or international equivalent standards. Ensure all lifting devices, chains and sling used comply with the requirements of - AS : lifting devices, AS : chain slings, AS : flat synthetic-webbing slings, AS fibre rope slings. lifting equipment (incl. hook block and attachments) must be appropriately marked in accordance with AS1418.1: part1 - general requirement or international equivalent standards. Ensure operators have the appropriate training and are deemed competent. Undertake a risk assessment ensure the appropriate risk controls are in place. Page 8 of 8

PLANT/EQUIPMENT/ASSET HAZARD REPORT

PLANT/EQUIPMENT/ASSET HAZARD REPORT Asset Description: EL-09100-060 : Gantry hoist system Sale Type For what use is this asset being sold? Re-Use Spare Parts Scrap Note 1: Assets are sold only for the use indicated. Any other use is at the