Procedure - QUT

Last modified: 3 December 2015 Reference Number: DHSE-PRO-0004 Document Name: DHSE-PRO-PlantProcedure.docx

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Procedure

Plant

Purpose 1.

The purpose of this procedure is to safeguard the health, safety and welfare of all persons at QUT through establishing a plant safety management system which can systematically identify, assess and control the risks arising from the use of plant.

Scope 2.

This procedure covers all employees and students that may be exposed to an increased health and safety risk through the use of plant.

Definitions 3.

Refer to DHSE-GLO-0001 – HSE Definitions.

Roles and responsibilities 4.

4.1. Managers/Supervisors or persons with management or control of plant

Must manage health and safety risk associated with the plant within their control.

Must provide the available information for eliminating or minimising health and safety risk associated with

plant in their control.

Must consult with the WHS representative and/or workers who carry out work for you who are (or are

likely to be) directly affected by a work health and safety matter throughout the risk management process.

Must consult, cooperate and coordinate the risk management process with all other persons who have a

work health or safety duty.

Must ensure all staff who operate plant for which a “Competency to Operate” (CTO) has been developed,

have been assessed as competent before being allowed to operate the plant unsupervised.

Should maintain a “Skills Matrix” for all staff within the Manager/ Supervisor’s control that hold a valid

licence and/or a CTO for plant operation.

Must ensure that all plant is installed, commissioned, inspected, tested, maintained and services by a

competent person and maintain maintenance and service records (either from internal or external providers) either electronically or in hard copy.

Should keep an up-to-date register of plant (see Plant Register Form) requiring regular inspection and

maintenance.

Must ensure that plant or equipment is maintained, inspected or tested in accordance with the

recommendation of the manufacturer’s or a competent person.

Must ensure that inspection and testing of plant occurs as per the manufacturer’s instructions and in

accordance with the regulations (see Test and Tag Procedure)

Must ensure that registrable plant is registered (see Plant Register Form) with the WHS regulator, that the

plant registration number is displayed on the item of plant and documentation for registrable plant is maintained.

Work Instruction (WI) to be made available prior to plant use. WIs may be displayed next to fixed plant,

and folders of WIs located where portable equipment is stored for easy reference by operators.

Manufacturer’s manuals and instructions should be kept in an accessible location.

Any emergency instructions relating to an item of plant should be clearly displayed on or near it.

https://qutvirtual4.qut.edu.au/group/staff/people/health-and-safety/resources/policies




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4.2. Employees/ contractors

Must use plant only in the manner for which it was designed.

Must take reasonable care for personal health and safety and must not adversely affect the health and

safety of other persons.

Must comply with any reasonable instruction and cooperate with any reasonable policy or procedure

relating to health and safety at the workplace.

Procedure 5.

5.1. Risk management

The Manager/Supervisor or nominee should perform a risk assessment for each item of plant within their scope of control from purchase to disposal. This is a means of ensuring that all plant used throughout the business is safe and without risks to the health and safety of personnel.

The risk management process will address the issues of:

design and construction

purchasing or hiring

installing and commissioning

positioning of plant

operation of plant

plant isolation

maintenance of plant

plant storage

decommissioning, dismantling and disposing

employee training

development of safe work procedures

maintenance of records.

The Plant Risk Assessment form should be used to record the risk assessment process. All completed plant risk assessments should be stored onsite, preferable electronically in SharePoint, Trim or MAPS.

5.2. Design and construction

Each piece of plant must conform to any Technical Standards that are called up into legislation (see

Annex B – Example of technical standards for a list of examples).

All electrical equipment must comply with the relevant Australian electrical legislation standards.

Note: Imported electrical equipment may not comply with Australian Electrical legislation or standards.

(For further details see Annex A - Design of plant).

5.3. Installing and commissioning

Any installing or commissioning of plant must be conducted by a competent person and must have regard to the manufacturer’s instructions.

5.4. Purchasing or hiring

A risk assessment (see Plant Risk Assessment Form) must be performed to all plant when considering the purchase or hire of machinery which may impact on a person’s health and safety. The plant supplier, must provide you with information about:

the purpose for which the plant was designed or manufactured

the results of any calculations, analysis, testing or examination

any conditions necessary for the safe use of the plant

any alterations or modifications made to the plant.

5.5. Positioning of plant

Each piece of plant should be positioned within the workplace so that there is adequate space (minimum of


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0.6m) for employees to use, clean, service, maintain and inspect plant.

5.6. Operation of plant

Where applicable plant must be isolated before maintenance commences following the Lockout Tagout (see Annex E – Lockout tagout) for the plant. Where plant cannot be isolated, alternate means of preventing accidental operation should be implemented. In these situations, work should be conducted under controlled procedures to allow for maintenance. e.g. A competent person (as authorised by the Manager/Supervisor or nominee) must be stationed at the controls of the plant and be in communication with the maintenance personnel at all times

5.7. Maintenance

Maintenance includes inspection, testing, servicing, maintenance or cleaning of plant.

Plant maintenance must be carried out according to the manufacturer’s instructions or in accordance with the recommendation of a competent person. In addition, a maintenance program applies for each major item of plant.

These maintenance programs cover the following:

allocated responsibilities for people dealing with inspections

standards against which plant should be maintained

frequency of maintenance

critical safety instructions, such as an isolation procedure (where necessary);

procedures for maintenance

periodic inspections (eg see Test and Tag Procedure)

specific tests

repaired or modified plant

any variations from normal operation or dangerous occurrences and any trends that may be occurring

maintenance records should be kept electronically if possible.

5.8. Plant storage

Plant not in use must be left in a state the does not create a risk to health or safety to any person.

5.9. Decommissioning, dismantling and disposing

Any decommissioning or dismantling of plant must be conducted by a competent person.

If the plant is sold;

it must be decontaminated before leaving the site (ie laboratory equipment)

written notice must be provided to the person to whom the plant is supplied stating;

the conditions of the plant;

any faults identified; and

if appropriate, that the plant must not be used until the faults are rectified.

Written notice does not have to be supplied for plant that is only intended for scrap or spare parts.

5.10. Training of employees

Each employee must be provided with adequate instruction on how to use or maintain plant before starting work with or on the plant. The manufacturer’s operation handbook must be consulted for the training requirements and must provide the minimum training specification to ensure operator competency. Additional operator competency standards can be obtained by referring to the person's qualifications, information from past employers/referees and the person's past work experience.

When an employee has completed competency based training to operate a specific piece of plant, the training information is to be documented and placed on the individuals personnel file and the “Training Skills Matrix” updated accordingly. (For further information see Annex D – Competency to operate)

5.11. Work instructions

Work Instructions (WIs) must be developed for each piece of plant, and these are to be available to all

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operators and maintainers, and be regularly updated. WIs are readily available for identified high risk plant in the WI folder. WIs may be displayed next to fixed plant, and folders of WIs located where portable equipment is stored for easy reference by operators.

Manufacturer’s manuals and instructions should be kept in an accessible location.

Any emergency instructions relating to an item of plant should be clearly displayed on or near it. These should be printed in colour, laminated and placed either in a folder where the equipment is stored, or displayed on a wall next to fixed equipment i.e. pedestal drills, lathes, bench grinders.

5.12. Records

Plant records for plant are to be kept current, retained for the life of the plant, and if sold, form part of the sale (see Plant Register Form).

The records are to contain:

plant identification, i.e. serial numbers, make, model

compliance statements or test certificates

inspections

maintenance

major rectifications or modifications

additional information that should be recorded includes

risk assessments carried out on the plant

training given to operators and maintenance persons

work procedures.

A plant log book must be developed for each item of plant that is subject to this procedure to maintain the records required above.

5.13. Controlling the risk

The Manager/Supervisor or nominee must work through the hierarchy of risk controls to choose the control that most effectively eliminates or, where that is not reasonably practicable, minimises the identified risk.

5.14. Maintaining and reviewing control measures

The Manager/Supervisor or nominee

Must ensure that implemented control measures are maintained so that they continue to protect workers

and other people from the identified hazards. (For further information see Annex C – Machine guarding and Annex E – Lockout tagout)

Must review and as necessary revise control measures.

5.15. Use of plant

The Manager/Supervisor or nominee must:

So far as is reasonably practicable, prevent unauthorised alterations to or interference with the plant

Take all reasonable steps to ensure the plant is only used for the purpose for which it is designed, unless

a competent person has assessed that the proposed use does not increase the risk to health and safety

Ensure all safety features, warning devices, guarding, operational controls

emergency stops are used in accordance with instructions and information provided

Ensure emergency stops are immediately accessible to each operator of the plant.

Each employee is required to use the plant in accordance with the employer’s instructions regarding plant use. The employee must use plant in a safe manner. This includes:

not misusing plant. This means the employee must use the plant

for purposes for which it was designed, e.g. do not exceed safe working loads of plant

take reasonable care of plant

taking care for other people's safety

using health and safety measures, such as safeguards, appropriately

Annex B - Examples of technical standards


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not interfering with, removing or rendering safety measures ineffective, e.g. by defacing safety signs, de-

activating safeguards.

The employee must inform the employer or person in control of the workplace of any faults in the plant,

e.g. faulty control switches or missing safeguards must be reported.

References 6.

Work Health and Safety Queensland Act 2011

Work Health and Safety Queensland Regulation 2011

Managing the risk of Plant in the workplace – Code Practice 2013

Associated documentation 7.

Guidance Information

Annex A – Design of a plant

Annex B - Examples of technical standards Annex C - Machine guarding Annex D - Competency to operate Annex E - Lockout tagout Annex F - Plant registration and qualifications

Procedures

DHSE-PRO-0002 – Risk management DHSE-PRO-0035- Test and tag

Forms

DHSE-FRM-0029 – QUT plant risk check DHSE-FRM-0011 – Plant risk assessment DHSE-FRM-0040 - Competency to operate

Document history 8.

Version Number Description Date Approved by

V1 Built using existing content 08 December 2014 Director, DHSE

V2 Update to reference Competency to Operate form 03 December 2015 Director, DHSE

https://www.legislation.qld.gov.au/LEGISLTN/CURRENT/W/WorkHSA11.pdf

https://www.legislation.qld.gov.au/LEGISLTN/CURRENT/W/WorkHSR11.pdf

http://www.deir.qld.gov.au/workplace/resources/pdfs/managing-risks-plant-cop-2013.pdff







Annex A - Design of plant


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This annex and associated appendix should be read in conjunction the Plant Procedure

1.1. Designers

Within QUT the designer will be any staff or student commissioning an item of plant to be manufactured or modified. Manufacturing departments may also take on these duties if modifications to the design are made during the manufacturing process.

The only exception to this will be group practical classes where the unit coordinator will undertake the relevant risk assessment process.

Designers must ensure, so far as is reasonably practicable, that the plant, substance or structure is designed to be without risks to the health and safety of persons (WHS Act 2011 s22).

This includes risks involved in the manufacturing process, installation, transport, use, maintenance, storage and disposal.

1.2. Manufacturers

Within QUT a manufacture is any staff, student or department that builds, machines, creates or modifies items of plants or components of plant.

The only exception to this will be group practical classes where the unit coordinator will undertake the relevant risk assessment process.

Manufactures must ensure, so far as is reasonably practicable, that the plant, substance or structure is manufactured to be without risks to the health and safety of persons (WHS Act 2011 s22).

This includes risks involved in the manufacturing process, installation, transport, use, maintenance, storage and disposal.

Safe design 2.

This aims to elimination any risk throughout the items lifecycle in the design stage. Where this is not reasonably practical then the risks should be minimised utilising the hierarchy of control.

Safe design must include a comprehensive documented assessment in the following areas:

Manufacturing processes

Installation and commissioning

Transportation (within and off campus)

Use/ systems of work

Reasonably foreseeable misuse

Maintenance

Emergencies (due to plant malfunctions)

Storage

Decommissioning/disposal

Further information is listed in Attachment – Safe design information.

Design stage 3.

Before manufacturing commences there are a number of steps that must be completed to ensure a safe design is achieved.

Including but not limited to;

Documented risk assessment covering all aspects of safe design (Table 1)

Documentation of the intended purpose of the item of plant

https://www.legislation.qld.gov.au/LEGISLTN/CURRENT/W/WorkHSA11.pdf#page=30




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Consultation with the manufacture regarding the item of plant

Consultation with a competent person to verify the design (this may also be the manufacture)

Provide information on any testing or inspections to be carried out on the item of plant

Steps are taking to ensure any relevant facilities are suitable and safe for the item of plant to be

installed, used, maintained and decommissioned (where applicable)

Document any system of work and competency of operators that are necessary for the safe use of the

plant (if necessary, must be completed before item of plant is used)

Document any emergency procedures (if any) that are required to be implemented if there is a

malfunction of the plant

If the manufacture advises the designer of additional hazards/risks without suitable controls, the

designer must revise the design to eliminate or minimise the risk

Manufacturing 4.

During the manufacturing stage the following steps must be adhered to;

Consultation with the designer of any additional hazards/risks if identified (this includes the entire

lifecycle of the item)

Ensure any identified hazards/risks are not incorporated into the item of plant during manufacturing

Consult with the designer in regards to any modifications to the item

Test and examine the plant is safe before use (this should be documented)

Ensure that the item is supplied with the appropriate information on safe use. Within QUT the

manufacturing department may refer this duty back to the research body commissioning the item and only supply information developed during the manufacturing process

Information supplied with the item of plant must include the following;

The purpose for which the plant was designed or manufactured

The results of any calculations, testing, analysis or examination

Any conditions necessary to ensure that the item of plant is without risks when used for a purpose for

which is was designed or manufactured or when carrying out any activity related to the plant

Risk assessment 5.

The risk assessment should consider all the items of plant and the staged of the life of the plant

During manufacture

Installation and Commissioning

Transportation

Use/Systems of Work

Maintenance

Emergencies

Storage

Decommission/Disposal



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Attachment - Safe design information

(Attachment to Annex A)

Manufacturing Plant specific conditions relating to the method of manufacture

instructions for fitting or refitting plant parts and their location on other components of

the plant or their housings where errors could be made when installing the plant

instruction where hot or cold parts or material may create a hazard

specifications of material

wiring diagrams

specifications for proprietary items, e.g. electric motors

component specifications including drawings and tolerances

assembly drawings

assembly procedures including specific tools or equipment to be used

manufacturing processes, e.g. requirements for welding

details of hazards presented by materials during manufacturing

safety outcomes for programming.

Transport, handling and storage of plant

dimensions and weight

indications for handling, e.g. application points for lifting equipment

conditions for storage

Installing and commissioning

exposure to dangerous parts before installing guards

lifting procedures

plant interacting with people

plant interacting with other plant, e.g. connected services and installations

stability during installation

the proposed method for installing and commissioning, including tests that should be

carried out

using special tools, jigs, fixtures and appliances necessary to minimise the risk of injury

during installation

concealed installations, e.g. gas or fuel lines

environmental factors affecting installation and commissioning.

Using, inspecting and testing plant

intended uses for the plant, including prohibited uses

operating procedures

safe entry and exit

requirements for maintenance and repair, e.g. nature and frequency of maintenance,

disposal of hazardous by-product and consumables

emergency situations, e.g. types of fire fighting equipment

exposure to hazardous substances

how environmental conditions effect using the plant

the results or documentation of tests and examinations carried out on the plant and

design

de-commissioning, dismantling and disposing of plant

known residual risks i.e. those that cannot be eliminated or sufficiently minimised by

design

details of control measures like personal protective equipment that should be used to

further minimise the risks associated with plant

guidance on administrative control measures

Requirements for special tools needed to use or maintain plant.

For registerable plant, the information provided by the designer to the manufacturer should include the plant design registration number to provide evidence the plant design has been registered under the WHS Regulations. The plant design registration number is not necessary where the manufacturing process relates to the development of a prototype to test the design.



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Annex B - Examples of technical standards The following table is a list of published technical standards that provide guidance on the design, manufacture and use of certain types of plant. These technical standards provide guidance only and compliance with them does not guarantee compliance with the WHS Act and Regulations in all instances. This list is not exhaustive.

Plant Description

Reference Number

Standard Title Design Make Use

Amusement Structures

AS 3533 Amusement Rides and Devices • • •

Cranes, including hoists and winches

AS 1418 (Series) Cranes Including Hoists and Winches • •

AS 4991 Lifting devices • • •

AS 2550 (Series) Cranes – Safe use •

Conveyers AS 1755 Conveyers - Safety requirements • • •

Electrical installation

AS 3000 Electrical installation (known as the Aust/NZ wiring rules)

•

Electrical installation within an industrial plant

AS/IEC 60204.1 Safety of machinery: Electrical equipment of machines-General requirements • •

Earthmoving machinery

AS 2294.1 Earthmoving machinery – Protective structures - General

• •

AS 2958.1 Earthmoving Machinery – Safety –Wheeled machines-Brakes

• • •

ISO 6165

Earthmoving machinery – Basic types – Identification and terms and definitions

•

ISO 6746-1

Earth-moving machinery - Definitions of

dimensions and codes - Part 1: Base machine

•

ISO 6746-2

Earth-moving machinery - Definitions of

dimensions and codes - Part 2: Equipment and attachments

•

ISO 7133 Earth-moving machinery - Tractor-scrapers – Terminology and commercial specifications

•

Explosive Powered tools

AS/NZS 1873 (Series)

Power-actuated (PA) hand-held fastening tools.

• • •

Hand-held electric tools

AS/NZS 60745 Hand-held motor operated electric tools – Safety – General requirements

• • •

Fall arrest AS/NZS 1891.1

Industrial fall-arrest systems and devices - Harnesses and ancillary equipment

• •

AS/NZS 1891.4

Industrial fall-arrest systems and devices - Selection, use and maintenance

•

BS EN 1263-1 Safety nets-Safety requirements, test methods

•

Gas cylinders AS 2030.1 Gas cylinders-General requirements (known as SAA Gas Cylinders Code )

• •

AS 2337.2 Gas cylinder test stations •

AS/NZS 3509 LP (Liquefied Petroleum Gas) Fuel -Vessels for Automotive Use.

• •

Industrial (Forklift) trucks

AS 2359 (Series) Powered industrial trucks • • •

Industrial rope access systems

AS 4488.2 Industrial rope access systems • • •

Lasers AS/NZS 2211 (Series)

Safety of laser products • • •

AS 2397 Safe use of lasers in the building and construction industry

•



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Plant Description

Reference Number


AS/NZS IEC 60825.1: 2011

Safety of laser products – Equipment classification and requirements

• • •

Lifts AS 1735 (Series) Lifts, escalators and moving walks (known as the SAA Lift Code)

• • •

Machinery AS 4024 (Series) Safety of machinery • • •

AS 1657 Fixed platforms, walkways, stairways and ladders-Design, construction and installation

• •

AS 1788.2 Abrasive wheels-Selection, care and use • • •

AS 1893 Code of practice for the guarding and safe use of metal and paper cutting guillotines

• • •

AS 2661 Vapour degreasing plant – Design, installation and operation – Safety requirements

• • •

AS/NZS 3947.3 Low-voltage switchgear and control gear, switches, disconnectors, switch-disconnectors and fuse combination units

• •

AS 61508.6 Functional safety of safety related systems • • •

AS/IEC 61511 Functional safety – Safety instrumented system for the process industry sector

• • •

AS 62061 Safety of machinery: Functional safety of safety-related electrical, electronic and programmable electronic control systems

• • •

ISO 13849.1 Safety of machinery: Safety-related parts of control systems-General principles

• • •

BS/IEC 6496-2 Safety of machinery, Electro sensitive protective equipment

• •

AS 1121.1 Agricultural tractor power take-offs - rear-mounted power take-off types 1, 2 and 3 - General specifications, safety requirements, dimensions for master shield and clearance zone

• •

AS 1636 Agricultural wheeled tractors - Roll-over

protective structures criteria and tests • •

AS/NZS 2153.1 Tractors and machinery for agriculture and forestry - Technical means for ensuring safety - General

• •

SAE J167 Overhead protection for agricultural tractors - Test procedures and performance requirements

• •

Miniature boilers AMBSC Code –Part 1

Copper Boilers - Issue 7-2001 • •

AMBSC Code –Part 2

Steel Boilers – Issue 4-1995 • •

AMBSC Code - Part 3

Sub-Miniature Boilers – Issue 1-2008 • •

AMBSC Code – Part 4

Duplex Boilers – Issue 1-2010 • •

Pressure equipment

AS/NZS 1200 Pressure Equipment • • •

AS 2593 Boilers – Safety management and supervision systems

• •

AS 2971

Serially produced pressure vessels • •

AS/NZS 3788

Boiler and pressure vessels – In service inspection

•

AS 3873 Boiler and pressure vessels – Operation and maintenance

•



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Plant Description

Reference Number


AS 3920.1 Assurance of product quality – Pressure equipment manufacture

• •

ASME I Power boilers • •

ASME II Materials • •

ASME V Non-destructive examination • •

ASME VII -1 Pressure vessels • •

ASME VII - 2 Pressure vessels – alternative rules • •

ASME VIII-1 Pressure vessels – Full NDE – for AS1210 class1h (h=1)

• •

ASME IX Welding and brazing qualifications • •

ANSI / NGV-2 Basic requirement of compressed natural gas vehicle fuel containers

• •

CSA B51 Part 2 High pressure cylinders for the on-board storage of natural gas as a fuel for automotive vehicles

• •

ISO 11439 High pressure cylinders for the on-board storage of natural gas as a fuel for automotive vehicles

• •

ISO/EN 13458 (Series)

Cryogenic vessels – Static vacuum insulated vessels

• • •

Pressure piping AS 4041

Pressure piping • •

Machinery guarding

AS 4024 (Series)

Safeguarding of machinery – general principles

• • •

ISO 12100 Safety of machinery – General principles for design

• • •

Scaffolding AS/NZS 1576.1 Scaffolding – general requirements • •

AS 1577 Scaffold planks • •

AS/NZS 4576 Guidelines for scaffolding •

Ladders AS/NZS 1892.1/1892.2/1892.3

Portable ladders • •

Spray painting AS/NZS 4114.1 Spray painting booths. Part 1: Design, construction and testing

• • •

AS/NZS 4114.2 Spray painting booths. Part 2: Installation and maintenance

•

Turbines BS/EN 60593-2 Rules for steam turbine acceptance tests •

API 612 Special purpose steam turbines for refinery services

•

Ventilation AS 1668.2 The use of ventilation and air conditioning in buildings

• • •

Work boxes- crane lifted

AS 1418.17 1996

Cranes (including hoists and winches) • •

AS 2550 Cranes – Safe use •

AS 3860 Fixed guideway people movers • • •

ISO 2374 Lifting appliances – Range of maximum capacities for basic models

• •



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Key:

Abbreviations Name

ANSI American National Standards Institute

API American Petroleum Institute

AMBSC Australian Miniature Boiler Safety Committee

AS Australian Standard

ASME American Society of Mechanical Engineers

AS/NZS Australian Standard / New Zealand Standard

BS British Standard

CSA Canadian Standards Association

EN Europaische Norm (European Standard)

IEC International Electrochemical Commission

ISO International Standards Organisation

NZS New Zealand Standards

SAE Society of Automotive Engineers

Annex C - Machine guarding


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This annex should be read in conjunction the Plant Procedure

1.1. Managers/supervisors

A person with management or control of plant must ensure that:

regular inspections of the plant are conducted at the workplace to ensure that the guarding remains

appropriate and remain in serviceable condition.

unauthorised alterations to or interference with the plant is prevented, so far as is reasonably practicable

all safety features, warning devices, guarding, operational controls, emergency stops are used in

accordance with instructions and information provided

if access to the area of plant requiring guarding is not necessary during operation, maintenance or

cleaning, the guarding is a permanently fixed barrier

if access to the areas requiring guarding is necessary during operation, maintenance or cleaning, the

guarding is an interlocked physical barrier

if it is not reasonably practicable to use a permanently fixed barrier or an interlocked physical barrier, the

guarding is a physical barrier that can only be altered or removed using a tool, or

if it is not reasonably practicable to use a permanently fixed barrier, an interlocked physical barrier or a

physical barrier fixed in position, the guarding includes a presence-sensing safeguarding system.

1.2. Workers

A worker must use plant in accordance with the employer’s instructions in a safe manner by:

not interfering with, removing or rendering safety measures ineffective, e.g. by defacing safety signs, de-

activating guarding.

Procedure 2.

2.1. Machine hazards identification and assessment

All machine guarding hazards must be identified and assessed and the appropriate control measures implemented.

Operators and maintenance personnel must be consulted as part of the development of any machine guarding with information and communication provided to others who may also use the equipment.

2.2. Installation of guards

Machines must be fitted with guards where practicable so as to prevent access to parts which may constitute a hazard to personnel (e.g. moving parts, very hot or very cold parts, etc).

The design and installation of guards must be such so as not to interfere with the normal operation or maintenance of the equipment.

2.3. Safety devices and interlocks

Interlocks (mechanical, electrical or electronic) would prevent the starting or operation of the machine if the guard is removed or tampered with. Interlocks must be designed so that they are as difficult as is practicably possible to tamper with or bypass.

Interlocks must also be fitted where practicable to all items of equipment which may present a hazard if removed or changed (e.g. openings on tanks under high pressure or high temperature, etc). Such interlocks must prevent the cover, door or lid from being opened whenever hazardous conditions exist

Where required, presence sensing devices (including light beams and curtains), which can sense the presence of a person or part of a person must be fitted and connected so as to prevent the plant from starting or operating wherever a person may be harmed. The automatic stop must be designed so that moving parts cannot be reached until the machine has come to a complete halt.



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Remotely started or operated plant must be fitted with presence sensing devices, and a warning sign with a flashing light and a loud warning sound which operate prior to starting.

Where guarding is considered insufficient or easy to tamper with, the erection of barriers or fences must be considered.

Particular care must be taken when interlocks and automatic stops are to be fitted to machines where an unscheduled stop may create additional hazards.

2.4. Maintenance, inspections and records

Machine guarding and interlocks must be inspected and maintained at regular intervals in accordance with manufacturers specifications. Full records of inspection and maintenance must be kept.

2.5. Lifting of guards

Manual handling considerations must be taken into account when installing guards which need to be regularly lifted (e.g. on vertical tracks or hinges)

References 3.

AS 4024 Safety of Machinery – General Principle

Annex D - Competency to operate


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Annex D - Competency to operate


This annex and associated attachments should be read in conjunction the Plant Procedure

1.1. Managers/supervisors

Must ensure operators receive adequate information, training, instruction and supervision, that operators

are competent, and that the equipment is used appropriately to minimise any health and safety risk.

Must maintain proof or relevant licences and competencies.

1.2. Employees/contractors

Must use plant only in manner for which it was designed.

Must not operate any plant unless supervised by a competent person authorised by their

Manager/Supervisor; or

Only operate plant if their have the relevant licences or have been assessed as competent to operate.

Procedure 2.

2.1. Licenses

In some situation a high risk licence is required. Those plant that require a high risk licence to operate are set out in WHS Regulation Schedule 3 and the associated level of competency in Schedule 4.

2.2. Competency to operate

To determine if an operator is competent Managers and Supervisors can request the following evidence:

a previous certificate of competency issued under the repealed WHS Regulation 2008 by WHSQ for the

relevant plant item

a statement of attainment or other nationally recognised qualification for the plant type they will be

operating

completed training at an industry training school, or an industry competency card for the relevant item of

plant

on-the-job training by an experienced and competent person which can be verified by logbooks or

previous employer references

structured in-house training in the use of a particular plant if resources are available at a workplace.

2.3. Supervision

An inexperienced worker or student should always operate plant under the direct supervision of a competent person. Direct supervision means oversight by the supervising person of the work that person for the purposes of:

directing, demonstrating, monitoring and checking the person's work in a way that is appropriate to the

person's competency level

ensuring a capacity to respond in an emergency situation.

To determine the level of supervision an operator requires, the Manager or Supervisor should take into account:

worker’s experience and competency

risks associated with the tasks

worksite conditions.

A reduced level of supervision should be proportionate to the person's competency and experience and not place the health and safety of the supervisor or any other person at risk.

https://www.legislation.qld.gov.au/LEGISLTN/CURRENT/W/WorkHSR11.pdf#page=596


Competency to operate Drill Press


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Attachment - Example of a CTO

(Attachment to Annex D)


Supervisor/team leader authorisation

Guidelines for the assessor

This assessment is to be completed after the employee has gained practical experience in the section, on

the above named Drill Press

The employee may use the manufacturer’s handbook, Work Instruction (WI) and/or service checklist as

an aid if required.

Assess the employee completing given tasks under normal working conditions.

The employee must be signed off as competent in all sections (as instructed) on the following page,

before being deemed competent to operate a Drill Press of the specific type covered by this assessment. Initials are required in each section.

The employee must be notified of any area/s where he/she is assessed as not yet competent. This will

allow the employee to arrange for further training in this area.

This CTO will expire in five years from date of issue.

Completed assessment sheets shall be given to the supervisor,

Assessor’s report

Result: ☐ Competent ☐ Not yet competent

Assessor:

Signature:

Date assessed:

Sign-off of person being assessed:

Do you have a CTO for a Drill Press? If yes, complete only Section 1 of this Assessment. If no, complete entire assessment.

☐ Yes ☐ No

Please perform a competency to operate assessment for:

Name:

Personnel no.:

Qualification:

Procedure reviewed on (insert date):

Specific (insert equipment name) to be assessed on:

Authorised by:

Name:

Signature:

Date:



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Task Competent Comments

Section 1: Familiarisation

Conduct a pre start check of the 1.machine.

* Who do you report any damage to?

Identify the main isolation switch. 2.

Identify the stop and start 3.switches/buttons.

Section 2: Prepare and operate (insert equipment name) as per WI

Work area inspected and hazards 4.controlled.

Correct drill selected and tightened 5.correctly in the chuck.

Correct speed selected for material 6.to be drilled, trial run is done to make sure.

Material set up and secured to drill 7.base before drilling.

Pilot hole drilled first if required. 8.

Drill allowed to reach maximum 9.speed before drilling.

Coolant used where necessary 10.and no excessive pressure used on feed lever.

Section 3: Shut down (insert equipment name)

Machine isolated correctly. 11.

Material removed. 12.

1Area left in safe condition. 13.

Drill removed from chuck and 14.stored.

Annex E - Lockout tagout


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This annex and associated attachments should be read in conjunction the Plant Procedure.

1.1. Managers and supervisors

Ensure that adequate technical consultation is undertaken with relevant University personnel and the

supplier/manufacturer during the procurement, design or selection of new equipment or plant systems. This is so that effective isolation can be achieved with lockout capacity, included as an integral part of the equipment.

Implement and ensure this isolation procedure and practices are enforced and applied consistently.

Provide sufficient resources and training to ensure staff and contractors are informed of these processes.

1.2. Contractors, University technical and trade staff

Check, select and apply the appropriate equipment isolation devices, methods and tags properly, as per

this or other specific QUT procedures.

Fill in all information required on any tag. Do not apply blank or incomplete tags to any equipment.

Remove all Personal Danger Tags and Locks when work is completed and it is safe to do so.

If it is unsafe to return equipment to service at end of a work period, apply an Out of Service tag and keep

the lock in place if required.

Where appropriate, communicate status of equipment to Help Desk or other stakeholders if equipment

remains locked out-out of service and why.

1.3. All other University staff (professional and academic)

Recognise and respect the intent of all isolation devices, tags and the lock outs applied by staff, that are

in place on any equipment in their local work area.

Do not remove any tags or locks unless they are either the person who originally placed the tag or they

are the supervisor who is fully aware of the equipment condition and is fully satisfied that it is safe to remove isolation. See Section 9.0.

General policy 2.

A clearly defined safe system of energy isolation of University plant is required to be understood and used

by all relevant persons, wherever work such as fault finding, maintenance, repair, cleaning or adjustment is undertaken. Such a system must involve lockout and the appropriate use of PDT or OOS tags, especially where the isolation point/s may not be under the workers’ sole effective control e.g.: out of sight of worker.

The accidental and unwanted sudden energising or activation of plant poses a critical risk of harm to the

persons working on the equipment, or it could cause further physical damage to the plant or equipment.

All isolation points must be clearly identified and labelled, with information on specific shutdown

conditions or sequences to be displayed at the point of isolation. This information may be provided by manufacturers / installers commissioning data, “as constructed” drawings or other similar information sources, and relevant University technical staff should be familiar with it.

Isolation and lock out capacity should be considered at initial design, modification or procurement phase

of plant life.

Emergency stop buttons or other quick stop devices must not be used to isolate plant, as these are not

intended for this purpose.

Where any person identifies an item of unsafe equipment or appliance, they must clearly distinguish that

item of equipment as unsafe to use, by completing and attaching an Out of Service Tag. See section 6.2 OOS tags.

Anyone can apply an Out of Service Tag. This applies to all University staff or contractors.

Tags should be made available from all relevant work areas.

Interference with attached locks or tags, misuse or unauthorised removal will be seen as a breach of the

WH & S Act and the Electrical Safety Act. For QUT staff members this may be seen as serious breach of



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the Code of Conduct and result in disciplinary action. Contractors may have their contract cancelled by the University.

See Attachment – Applying plant isolation and tags

Tags – General 3.

A tag is not an effective isolation device on its own. A tag only conveys information to others on the job.

The correct type of tag must be used for the situation and applied correctly. Misuse of either tag for cross

purposes, irrespective of good intentions, may cause misunderstanding leading to equipment to be switched on, resulting in injury or death.

All tags must be filled out properly with all required information when applying the tag. Importantly, tags

must be current, dated and signed, with the mobile phone number and details of the person who placed it clearly and legibly written.

A supervisor or other designated responsible person is then able to check with the right person who

placed the tag, before deciding to remove any tag or continue to abide by its instruction.

This practice applies to both types of tags and helps differentiate between a critical situation and a

forgotten tag left on site.

3.1. Use of personal danger tags (PDTs)

Every person, while working on isolated equipment must apply their own PDT to each isolation point

during a shutdown or similar situation.

The person who placed the PDT must remove it at the end of their work shift or day.

An Out of Service Tag should be applied in the place of a removed danger tag, for overnight or any

period, until work resumes again. See Section 9.0

3.2. Out of service tags (OOS)

When an Out of Service Tag is attached to an appliance or equipment, it must not be operated.

The tag must be securely fixed to the operating control power isolator with details explaining the reasons

for the equipment being withdrawn from service.

The tag must not be removed until the equipment is made safe (repaired, inspected or tested) and it is

returned to service or the reason for the tag no longer exists.

The repairer should contact the person who placed the OOS tag and notify them of the status of the

equipment before return to normal service.

Locking out equipment 4.

4.1. Isolation devices

Locking out equipment is a secure method of physically preventing machinery or energy from becoming

operational during maintenance or similar work.

There are a wide range of devices for locking out energy sources including built in lock, lockouts for circuit

breakers, fuses and all types of valves. Additionally there are chains, and safety lockout jaws (hasps) which can accommodate multiple padlocks.

Only devices that incorporate a lock or can accommodate one or more padlocks are suitable lockout

devices.

4.2. One person – one lock

Each person working on the equipment must have their own lock /s or other lockout device.

A Personal Danger Tag must be used in conjunction with each lock to inform others that this person is on

site and working on the equipment, while the lock and tag are in place.

The lock must only be removed by the person who attached it.

4.3. One lock – one key

There must not be any duplicate keys for any lock.

The one key for each person’s lock should be held only by that person, who is responsible for both

locking and unlocking the lockout device.



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4.4. Multiple energy sources

Where there is more than 1 energy source or hazard that has to be locked out, a lockout plan should be

developed with the responsible supervisor, to ensure a safe and effective isolation.

For each lockout device, the single key principle applies. Each worker must be able to establish effective

control over every energy source.

Lock out or isolation application (general procedure) 5.See Attachment – Applying plant and isolation tags

5.1. Communicate and initiate isolation of machinery or equipment

Prior to a planned isolation or shutdown that will affect building occupants, communicate to the Facilities Management Help Desk of the intended isolation process. Where appropriate, building occupants should be informed of impending isolations, especially if it is likely to significantly impact their normal work activities, excluding testing of fire systems.

5.2. Identify all energy sources likely to activate the equipment and expose persons to hazards

electricity (mains); 15.

mechanical parts continuing to move through inertia 16.

mechanical parts liable to move by gravity 17.

fluids or gases under pressure (water, air, steam or hydraulic oil) 18.

battery, capacitors or accumulators 19.

solar panels 20.

pressurized fluids 21.

stored energy (e.g. compressed springs) 22.

fuels 23.

heat 24.

steam 25.

radiation. 26.

5.3. Identify all isolation points

Original designer or installer “as built” diagrams of equipment installations should be available for identifying all isolation points. Alternatively new diagrams or photographs showing locations and details of isolation points should be developed for specific isolation procedures.

5.4. Isolate all energy sources

Use of operating stop buttons, emergency stop devices or reliance on interlocking devices is not equivalent to the proper isolation of power sources or release of stored energy.

5.5. De-energise all stored energies

Use all relevant methods to protect against energy remaining in the equipment or system even after removal from energy source, including.

Inspect equipment to ensure all parts have stopped moving

Block parts in hydraulic or pneumatic systems that could move from pressure loss

Bleed lines and leave vent valves open

Drain piped systems and close valves to prevent flow of material

Install ground wires

5.6. Lockout all isolation points – See Section 7.0

5.7. Apply a personal danger tag

A PDT must be used in conjunction with every lockout, and applied to every energy isolation point or lock out device included in the lock out.



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5.8. Test isolation

Check the effectiveness of isolation by ‘trying’ to reactivate the plant without exposing the tester or others to risk (failure).

Removal of lockouts and personal danger tags (general procedure) 6.

See Attachment – Removal of locks and tags on isolated plant

The majority of maintenance work at QUT requiring lock out and tags, is usually completed on the same 1.day. In this case, the process for removal of locks and PDT tags is straightforward, but there are exceptions or times where a changeover of isolations is necessary.

Personal Danger tags & locks must be removed only by the person who placed them, at the end of the 2.day or work period.

In the event the locks and tags are not removed, the supervisor or project co-ordinator of the work must: 3.

determine the location of the owner of the PDT and lock; a.

check the status of the equipment, b.

conduct an assessment of the risk and then if satisfied, c.

authorise the removal of the tag. d.

However, the lock should remain in place if the lock owner is unable to physically remove the lock, e.g.: 4.injury’, until alternative authorised isolation arrangements are organised e.g.: replacement with current authorised lock and PDT tag.

The remaining lock and tags can then be removed by the work supervisor or project co-ordinator after 5.they are satisfied it safe to do so, after following all precautions in step 8.3. They may specifically delegate that authority to others as required.

In situations (excluding above 8.3), where equipment remains in an unsafe or unusable condition 6.overnight or for an extended period, and work is due to resume within a reasonably short time i.e.: next day, after meal break etc, then at least one lock must remain in place, and the Personal Danger Tag replaced by a single completed Out of Service tag.

When work resumes, the remaining OOS tag is to be removed and a PDT is re-applied for each worker 7.as per normal practice.

References 7.

AS 4024.1101-2006

AS/NZS 4836 – Safe working on low-voltage electrical equipment

AS 1318 – 1985 - Safety Signs for the Occupational Environment



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Attachment – Images

(Attachment to Annex E)

Image 1: Personal Danger Tags and Out of Service Tags as per AS1318.

Image 2: Multi-Hasp Lock Out device, Single locks and PDTs in place.

Image 3: Single & Multiple locks and other lockout devices



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Attachment - Applying plant isolation and tags


1. Begin process of planned isolation or shutdown (If the Isolation will affect Building Occupants contact the FM Help Desk to informed them of the intended isolation, location and reason why). Where appropriate, building occupants should be informed of impending isolations, especially if it is likely to significantly impact their normal work activities.

2. Find all energy sources that relate to the item of plant including electrical ( mains, photovoltaic cells, solar and generator); fuel, heat, steam, fluids under pressure (water, air or hydraulic oil); energy storage devices (batteries, springs, accumulators and capacitors), gravity activated (flywheels, pulleys); & radiation.

3. Check “as built” diagrams of installation, new diagrams, commissioning reports; and consult with experienced relevant persons to ensure all isolation points are confirmed.

4. Do not use or rely on Emergency Stop buttons; Remote electronic Building System Operating stop systems or installed interlocking devices used under normal operation. Turn off main isolating switches, valves, pumps etc.

5. Remove or dissipate all stored energies – block hydraulic or pneumatic systems to relieve pressure; bleed lines; open vent valves; drain piped systems, close valves to prevent flow of material; install ground wires.

6. Securely apply lock out devices as per Section 6.0 to inbuilt lock mechanisms; lockouts for circuit breakers; fuses and all types of valves; chains and safety lockout jaws or hasps for multiple padlock attachment.

1 person; 1 lock,

1 lock ; 1 key

7. Attach a Personal Danger Tag for each person and to every

isolation point included in the isolation.

8. Check the effectiveness of the isolation by trying to reactivate or start the equipment – without placing the tester and others to risk of injury i.e.: do not enter the system until test isolation is confirmed.

9. Commence work in protected environment

2. IDENTIFY all energy sources

1. Begin isolation of equipment or machinery

3. IDENTIFY all isolation points

4. ISOLATE ALL Energy Sources

5. DE-ENERGISE all stored energies

6. Lock out all Isolation Points

7. Apply a Personal Danger Tag (PDT)

8. Test all Isolations

9. Commence Repair or Maintenance Work



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Attachment – Removal of locks and tags on isolated plant


1. Check with person in charge of work

that it is safe and timely to remove any isolation devices and tags from the equipment. Authorisation is given and confirmed.

2. Personal danger tags (PDTs) and locks are only to be removed by the person who placed them except in special circumstances. See step # 4

3. The majority of work is usually completed on the same day; however there will be occasions when a changeover of isolations is necessary.

4. Where equipment remains unsafe or unusable overnight or for a period, at least one (1) lock must remain in place to isolate (if possible)and the PDT is replaced by an Out of Service (OOS) tag. The OOS tag states all appropriate information and contact numbers.

5. Work resumes, overnight OOS tag removed and new PDT is applied for each person, as per normal practice. Additional locks are applied to remaining lock as required to achieve isolation.

6. Lock and tag owner is physically unable to attend site to remove their isolation, due to injury or physical distance from site.

7. Remaining lock must remain in place until owner returns to site to remove it, or alternate authorised arrangements confirmed.

8/9. Supervisor or Project Co-ordinator must confirm:

Location of lock owner

Status of equipment

Assess risk

Authorise removal of lock and/or PDT tag OR RETURN to normal service.

10. Equipment is returned to full operation

and area is made safe – cleaned. Inform the FM Help Desk 83000 if necessary.

1. Work is complete

Confirm authorisation to remove isolation devices and personal danger tags at end of work

or day.

Yes

10. Equipment is returned to safe operational status.

Yes

2. Each person removes their own lock and /or

personal danger tag for each isolation point.

No

6. Locks and PDTs are not or cannot be removed by person who placed them.

7. Locks & tags to remain in place if lock

owner physically unable to remove them.

8. Supervisor to

assess situation

9. Supervisor authorises removal of tag or lock and return

to normal operation or replacement of new authorised lock and

PDT.

3. Work is not complete and a

changeover of isolation

is required.

4. A minimum of one (1) lock and an Out of

Service tag is

maintained on the equipment.

5. Work resumes, OOS tag is removed and PDT and locks are

reapplied as per normal practice until work is

completed and Step 2 is achieved.

No

Annex F - Plant registration and qualifications


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Annex F - Plant registration and qualifications There are potential risks associated with operating certain plant and equipment, and performing particular activities.

Plant and equipment must be maintained in accordance with the manufacturer specifications.

All required operator qualifications/licences/approvals/competency to operate must be verified and recorded against the workers profile.

High Risk Plant / Equipment OHS Category Operator Quals*

Air-conditioning units (greater than 50kW) R n/a

Amusement devices (excluding coin operated devices) R n/a

Autoclaves QUT QUT

Boats QUT L

Boilers (Hazard level A, B or C) R HL

Building Maintenance Units R HL

Chainsaws QUT C

Cooling towers HR n/a

Crane and Hoist QUT HL

Elevated Work Platform QUT QUT

Escalators (including moving walkways) HR, R n/a

Forklift (forklift tuck, order picking forklift truck) QUT HL

Fume Cupboard / Biosafety Cabinet QUT QUT

Heavy Vehicle QUT L

Lifts HR, R n/a

Light Vehicles QUT DL

Light Vehicles (4WD; driving off-road) QUT DL, C

Load shifting equipment (dozer, excavator, front-end loader, front end loader/backhoe, grader, road roller, scraper, skid steer loader)

QUT C

LP Gas Cylinders (water capacity > 0.1kg) HR n/a

Mobile Crane (greater than 10t) R HL

Motorbike QUT L

Pendant Cranes QUT QUT

Pressure Vessels / Equipment (boiler, turbine, steam engine) R HL

Quad Bikes QUT DL, C

Ride on Mowers QUT DL, QUT

Tractors QUT DL, C

Truck-mounted concrete placing units with booms R L

Utility Vehicles (e.g. Kubota / Kawasaki) QUT DL, QUT

OHS Categories / Definitions:

High Risk Plant (HR): As per Schedule 1 of the Work Health and Safety Act 2011

Plant to be registered (R): As per Schedule 5 of the Work Health and Safety Regulation 2011

High Risk Work Licence (HL): As per Schedule 3 of the Work Health and Safety Regulation 2011

QUT: Queensland University of Technology defined high risk plant, with specific plant maintenance requirements and/or training requirements to operate.




Annex F - Plant registration and qualifications


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* Operator Licences / Certificates / Training

L C QUT DL

Licence / Authority to work (certificate)

Certified Training via Registered Training Organisation (RTO)

QUT Training Drivers Licence

Training.gov.au (TGA)

A joint initiative of Australian State and Territory Governments, training.gov.au encompasses the national register which contains the authoritative information about Registered Training Organisations (RTOs), recognised training products and the approved scope of each RTO to deliver nationally recognised training as required in national and jurisdictional legislation within Australia.

Documents

Procedure - QUT