NHP Safety of Machinery - Hazard/Task Analysis & Risk Assessment Using AS4024.1:2014

• Document No.

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

Document Revisions

• Document Revisons

Document Revision

• Revised By?

• Date of Revision

  Date

• Signature of Document Editor

  Sign

Site Documentation viewed

• Electrical Drawings

  Yes

  No

  N/A

• Hydraulic Circuits

  Yes

  No

  N/A

• Pneumatic Circuits

  Yes

  No

  N/A

• Mechanical Layouts

  Yes

  No

  N/A

• Operating manuals

  Yes

  No

  N/A

• Maintenance Manuals

  Yes

  No

  N/A

• Safety Instructions

  Yes

  No

  N/A

• Material Safety Data Sheets

  Yes

  No

  N/A

Site or Plant Contacts

• Personnel Interviewed About Machinery

Site Contacts

• Name

• Position

Purpose of this Assessment

• Purpose of this assessment is to provide the recipient company with advice and guidance relating to the safety of the plant, equipment or machinery being assessed. All relevant Australian and European standards applicable will be used to assess each hazard.

Motivation of Company requesting this assessment

Service Provided

• The risk assessment model being used is a widely acceptable form of examination for plant, equipment or machinery and work practices. The approach is a standardized set of approaches governing hazard identification, evaluating that risk posed to personnel. The assessment will give the reader an informed view on how likely a hazard would be to occur and what could be done to mitigate against the hazard occurring in the future.

Phases of machine operation being assessed

• Transport

  Yes

  No

  N/A

• Cleaning

  Yes

  No

  N/A

• Maintenance / Repair

  Yes

  No

  N/A

• De-commisioning

  Yes

  No

  N/A

• Operation

  Yes

  No

  N/A

• Disposal<br>

  Yes

  No

  N/A

• Installation

  Yes

  No

  N/A

• Assembly / Installation

  Yes

  No

  N/A

Basic Machine Limits

• Manufacturer / OEM

• Machine Importer or supplier

• Machine Name

• Machine Serial Number

• Are operators trained to use equipment?

  Yes

  No

  N/A

• Who is responsible for maintenance & repair?

• Who is responsible for cleaning and clearing of jams etc?

• Are maintenance staff trained on equipment?

  Yes

  No

  N/A

• What is the normal maintenance interval?

  Select Daily Weekly Monthly Bi-Monthly 6 Monthly Yearly

  • Daily
  • Weekly
  • Monthly
  • Bi-Monthly
  • 6 Monthly
  • Yearly

• Is machine being used in it's intended environment?

  Yes

  No

  N/A

• Basic Description of Control System

• What is the control voltage?

  24vdc

  48vdc

  24vac

  110vac

  240vac

• What is the main power supply voltage?

  110vac

  240vac

  415vac 3 phase

• Does the machine have Hydraulic Controls

  Yes

  No

  N/A

• What is the Hydraulic Pressure in Bar?

• Does the machine have Pneumatics controls?

  Yes

  No

  N/A

• What is the Compressed Air Pressure in Bar?

Details relating to hazard and tasks

• Description of all Hazards

Hazard

• Photograph of Hazard

  Media

• Area of Machine associated with hazard?

  Select In-Feed Out-Feed Operator Control / Machine Side Maintenance / Setup Machine Rear Hydraulic System Pneumatic System

  • In-Feed
  • Out-Feed
  • Operator Control / Machine Side
  • Maintenance / Setup
  • Machine Rear
  • Hydraulic System
  • Pneumatic System

• Task or operation?

  Select Construction Transportation Assembly & Installation Commissioning Setting/ Programming/ Changeover Operation Cleaning / Maintenance Fault Finding / Trouble shooting Decommissioning and dismantling

  • Construction
  • Transportation
  • Assembly & Installation
  • Commissioning
  • Setting/ Programming/ Changeover
  • Operation
  • Cleaning / Maintenance
  • Fault Finding / Trouble shooting
  • Decommissioning and dismantling

• Types of Hazards associated with the task?

  Select Mechanical Electrical Thermal Noise Vibration Radiation Materials or Substances Ergonomic / RSI Combination of Hazards Unexpected Start-up, Unexpected Overspeed or overrun Unable to stop machine in best conditionVariations on the rotational speed of the tools Human Error / Human Behaviour Fire and Explosion Emmision of Gas and/or Dust etc. Third Person involvement Inadequate training or SOP's Due to power source or transmission of power Due to control system Failure of power supply Failure of controls system loss of stability Slip, trips or Falls Variable Speed of rotation or tools or hazards Linked to work position Errors of fitting, loading Break up during operation

  • Mechanical
  • Electrical
  • Thermal
  • Noise
  • Vibration
  • Radiation
  • Materials or Substances
  • Ergonomic / RSI
  • Combination of Hazards
  • Unexpected Start-up, Unexpected Overspeed or overrun
  • Unable to stop machine in best conditionVariations on the rotational speed of the tools
  • Human Error / Human Behaviour
  • Fire and Explosion
  • Emmision of Gas and/or Dust etc.
  • Third Person involvement
  • Inadequate training or SOP's
  • Due to power source or transmission of power
  • Due to control system
  • Failure of power supply
  • Failure of controls system
  • loss of stability
  • Slip, trips or Falls
  • Variable Speed of rotation or tools or hazards
  • Linked to work position
  • Errors of fitting, loading
  • Break up during operation

• Hazard Description

Hazard Rating Number - multiply DPH x FE x LO x NP to get HRN - the number determines the Risk Level.

• DPH - Degree of Possible Harm

  Select 0.1- Scratch / Bruise 0.5 - Laceration / cut / Mild ill health 1 - Fracture Minor Bone - fingers / toes 2 - Fracture Major Bone - Hand / Arm / Leg 4 - Loss of some fingers or toes 8 - Loss of Leg / Arm or hand, partial loss of hearing or sight 10 - Amputation of both Arms or Both Legs, total loss of sight or hearing 12 - Critical Permanent IIIllness 15 - Fatality

  • 0.1- Scratch / Bruise
  • 0.5 - Laceration / cut / Mild ill health
  • 1 - Fracture Minor Bone - fingers / toes
  • 2 - Fracture Major Bone - Hand / Arm / Leg
  • 4 - Loss of some fingers or toes
  • 8 - Loss of Leg / Arm or hand, partial loss of hearing or sight
  • 10 - Amputation of both Arms or Both Legs, total loss of sight or hearing
  • 12 - Critical Permanent IIIllness
  • 15 - Fatality

• FE - Frequency of Exposure

  Select 0.5 - Annually 1 - Monthly 1.5 - Weekly 2.5 - Daily 4 - Hourly 5 - Constantly

  • 0.5 - Annually
  • 1 - Monthly
  • 1.5 - Weekly
  • 2.5 - Daily
  • 4 - Hourly
  • 5 - Constantly

• LO - Likelihood of Occurance

  Select 0.033 - Almost Impossible 1 - Highly Unlikely 1.5 - Unlikely 2 - Possible 5 - Even Chance 8 - Probable 10 - Likely 15 - Certain

  • 0.033 - Almost Impossible
  • 1 - Highly Unlikely
  • 1.5 - Unlikely
  • 2 - Possible
  • 5 - Even Chance
  • 8 - Probable
  • 10 - Likely
  • 15 - Certain

• NP - Number of Persons affected / in hazardous area

  1 > 1-2 persons

  2 > 3-7 persons

  4 > 8-15 persons

  8 > 16-50 persons

  12 > More than 50 persons

• HRN - Hazard Rating Number ( LO x FE x DPH x NP = HRN)

  Select 0-1 Negligible Risk 2-5 Very Low Risk 6-15 Low Risk 16-50 Significant Risk 51-100 High Risk 101-500 Very High Risk 501 > Extreme Risk

  • 0-1 Negligible Risk
  • 2-5 Very Low Risk
  • 6-15 Low Risk
  • 16-50 Significant Risk
  • 51-100 High Risk
  • 101-500 Very High Risk
  • 501 > Extreme Risk

Residual Risk Reduction

• Residual Risk Reduction Measures

• DPH - Degree of Possible Harm after Risk Reduction

  Select 0.033 - Almost Impossible 1 - Highly Unlikely 1.5 - Unlikely 2 - Possible 5 - Even Chance 8 - Probable 10 - Likely 15 - Certain

  • 0.033 - Almost Impossible
  • 1 - Highly Unlikely
  • 1.5 - Unlikely
  • 2 - Possible
  • 5 - Even Chance
  • 8 - Probable
  • 10 - Likely
  • 15 - Certain

• FE - Frequency of Exposure after Risk Reduction

  Select 0.5 - Annually 1 - Monthly 1.5 - Weekly 2.5 - Daily 4 - Hourly 5 - Constantly

  • 0.5 - Annually
  • 1 - Monthly
  • 1.5 - Weekly
  • 2.5 - Daily
  • 4 - Hourly
  • 5 - Constantly

• LO - Likelihood of Occurrence after Risk Reduction

  Select 0.033 - Almost Impossible 1 - Highly Unlikely 1.5 - Unlikely 2 - Possible 5 - Even Chance 8 - Probable 10 - Likely 15 - Certain

  • 0.033 - Almost Impossible
  • 1 - Highly Unlikely
  • 1.5 - Unlikely
  • 2 - Possible
  • 5 - Even Chance
  • 8 - Probable
  • 10 - Likely
  • 15 - Certain

• NP - Number of Persons affected / in hazardous area

  1 > 1-2 persons

  2 > 3-7 persons

  4 > 8-15 persons

  8 > 16-50 persons

  12 > More than 50 persons

• HRN - Hazard Rating Number ( LO x FE x DPH = HRN) after Risk Reduction

  Select 0-1 Negligible Risk 2-5 Very Low Risk 6-15 Low Risk 16-50 Significant Risk 51-100 High Risk 101-500 Very High Risk 501 > Extreme Risk

  • 0-1 Negligible Risk
  • 2-5 Very Low Risk
  • 6-15 Low Risk
  • 16-50 Significant Risk
  • 51-100 High Risk
  • 101-500 Very High Risk
  • 501 > Extreme Risk

Category of Control required (AS4024.1501:2014) if Guarding solution requires SRP/CS and not just a mechanical guarding.

• Severity of Hazard

  Select S1 - Bruise or mild laceration S2 - severe injury, lost time > fatality F1 - infrequent /short exposure F2 - frequent and/or long exposure P1 - possible to avoid under normal conditions P2 - not possible to avoid under normal conditions

  • S1 - Bruise or mild laceration
  • S2 - severe injury, lost time > fatality
  • F1 - infrequent /short exposure
  • F2 - frequent and/or long exposure
  • P1 - possible to avoid under normal conditions
  • P2 - not possible to avoid under normal conditions

• AS4024.1-2014 Category B+1
  
  Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned.
  
  Category 1 - Well Tried Safety Components and principles - widely used with successful components, made and verified for use in safety circuits.

• Frequency of Hazardous Event

  Select S1 - Bruise or mild laceration S2 - severe injury, lost time > fatality F1 - infrequent /short exposure F2 - frequent and/or long exposure P1 - possible to avoid under normal conditions P2 - not possible to avoid under normal conditions

  • S1 - Bruise or mild laceration
  • S2 - severe injury, lost time > fatality
  • F1 - infrequent /short exposure
  • F2 - frequent and/or long exposure
  • P1 - possible to avoid under normal conditions
  • P2 - not possible to avoid under normal conditions

• Possibility of Avoiding the Hazard(s)

  Select S1 - Bruise or mild laceration S2 - severe injury, lost time > fatality F1 - infrequent /short exposure F2 - frequent and/or long exposure P1 - possible to avoid under normal conditions P2 - not possible to avoid under normal conditions

  • S1 - Bruise or mild laceration
  • S2 - severe injury, lost time > fatality
  • F1 - infrequent /short exposure
  • F2 - frequent and/or long exposure
  • P1 - possible to avoid under normal conditions
  • P2 - not possible to avoid under normal conditions

• AS4024.1-2014 Category 1 (with over-dimensioning and Fault exclusion) or Category 2
  
  Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned.
  
  Category 1 - Well Tried Safety Components and principles - widely used with successful components, made and verified for use in safety circuits.
  OR
  Category 2 - Category B shall apply + safety functions shall be checked by the machine control system at suitable intervals. If manual checks are performed then this should be documented. Check shall generate a fault indication if a fault is detected

• AS4024.1-2014 Category 2 (with over-dimensioning and Fault exclusion) or Category 3
  
  Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned.
  
  Category 2 - Category B shall apply + safety functions shall be checked by the machine control system at suitable intervals. If manual checks are performed then this should be documented. Check shall generate a fault indication if a fault is detected
  OR
  Category 3 - Category B shall apply + shall be designed so that a single fault in any part of the SRP/CS does not lead to a loss of safety function. Wherever reasonably practicable, the single fault shall be detected at or before the next demand upon the safety function.
  

• Possibility of Avoiding the Hazard(s)

  Select S1 - Bruise or mild laceration S2 - severe injury, lost time > fatality F1 - infrequent /short exposure F2 - frequent and/or long exposure P1 - possible to avoid under normal conditions P2 - not possible to avoid under normal conditions

  • S1 - Bruise or mild laceration
  • S2 - severe injury, lost time > fatality
  • F1 - infrequent /short exposure
  • F2 - frequent and/or long exposure
  • P1 - possible to avoid under normal conditions
  • P2 - not possible to avoid under normal conditions

• AS4024.1-2014 Category 3
  
  Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned.
  
  Category 3 - Category B shall apply + shall be designed so that a single fault in any part of the SRP/CS does not lead to a loss of safety function. Wherever reasonably practicable, the single fault shall be detected at or before the next demand upon the safety function.
  

• AS4024.1-2014 Category 4
  
  Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned.
  
  Category 4 - Category B shall apply + a single fault in SRP/CS does not lead to loss of safety function and the single fault is detected at or before the next demand of the safety functions i.e. immediately or at the end of the machine operating cycle. If detection is not possible then an accumulation of faults shall not lead to a loss of safety function.