Managing the Risk of Plant in the Workplace Minimum Standard

Managing the Risk of Plant in the Workplace Minimum Standard

TBA, 2017

Contents

1Executive Summary

2More Information

3Using this Standard

4Standard Provisions

4.1Introduction

4.1.1Who has health and safety duties in relation to plant at the workplace

4.2The Risk Management Process

4.2.1Identifying risk

4.2.2Assessing the risk

4.2.3Controlling the risk

4.2.4Maintaining and reviewing risk control measures

4.3Controlling Risks: From Purchase to Disposal

4.3.1Purchasing and Hiring plant

4.3.2Installation and commissioning of plant

4.3.3Instruction, training and supervision

4.3.4Using plant in the workplace

4.3.5Making changes

4.3.6Inspecting plant

4.3.7Maintenance, repair and cleaning of plant

4.3.8Storing plant

4.3.9Decommissioning, dismantling and disposing of plant

4.3.10Guarding plant and Operator controls

4.3.11Emergency stops

4.3.12Warning devices

4.3.13Isolation of energy sources

4.4Plant registration

4.5Keeping records

5Responsibilities

6Glossary

7Supporting Documentation

8Versioning

Responsible Officer / Executive Director – Human Resources
Approved by / Executive Director – Human Resources
Approved and commenced / TBA, 2017 /
Review by / Month, 20XX
Relevant Legislation, Ordinance, Rule and/or Governance Level Principle the Standard supports / Work Health and Safety Act 2012 (Tas)
WorkHealth and Safety Regulations 2012 (Tas)
Responsible Organisational Unit / Work Health and Safety Unit – Human Resources

1Executive Summary

The University is committed to continuously improvingthe management and standards of Work Health and Safety. This extends to eliminating where reasonably practicable or minimising the risks associated with Plant in the Workplace.

The objective of this Minimum Standard is to provide support to Organisational Unit Heads and advice to workers for managing the risk of plant in the workplace.

2Scope

This Minimum Standard applies to plant which includes any machinery, equipment, appliance, container, implement and tool and includes any component or anything fitted or connected to any of those things. It includes items as diverse as lifts, cranes, computers, machinery, conveyors, forklifts, vehicles, electrical equipment, power tools, hand held tools, hand trolleys and workshop equipment.

It includes the University’s requirements of purchase, maintenance, repair, installation, service, cleaning and inspection, induction and training and operation of plant.

3More Information

For further information, contact the Human Resources – Work Health and Safety Unit and/or Infrastructure Services and Development(ISD).

Email:

4Using this Minimum Standard

ThisMinimum Standardhas been developed to ensure compliance with the following Acts, Regulations and Codes of Practice:

  • Work Health and Safety Act 2012; and
  • Work Health and Safety Regulations 2012

This Minimum Standardis to be applied in conjunction with the Code of Practice:

  • Managing Risk of Plant at the Workplace

This Minimum Standard is to be read in conjunction with the University’s:

  • Risk Management Policy
  • Risk Assessment Procedure
  • Safe Work Procedure
  • Asset Management Policy
  • Managing Noise and Preventing Hearing Loss Minimum Standard
  • Electrical Equipment – Inspection, Testing and Tagging Procedure
  • Purchasing Work Health and Safety Procedure
  • Procurement Policy
  • Workplace Inspection Procedure
  • Plant Isolation – Lock out/Tag out Procedure
  • Personal Protective Equipment Procedure
  • Health Monitoring Minimum Standard
  • Confined Space Entry Procedure
  • Permit to Work Procedure
  • Records Management Policy

5Standard Provisions

The University has the primary duty to ensure, so far as is reasonably practicable:

  • The provision and maintenance of safe plant
  • The safe use, handling, storage and transport of plant
  • Management of the health and safety risks associated with plant
  • Prevention of unauthorised alterations to or interference with plant
  • Usage of plant only for the purpose for which it was designed unless the proposed use does not increase the risk to health or safety.

5.1Responsibilities

There are significant risks associated with using plant, and severe injuries can result from the unsafe use of plant, including:

  • Limbs amputated by unguarded moving parts of machines
  • Being crushed by mobile plant
  • Sustaining fractures
  • Electric shock
  • Burns or scalds due to contact with hot surfaces, or exposure to flames or hot fluids.
  • Other risks include hearing loss due to noisy plant and musculoskeletal disorders caused by manually handling or operating plant

The Manager/Supervisor of each Organisational Unit is to manage the risks of plant by following the systematic process provided in the Code of Practice:

  • organising the inspection, testing and monitoring of plant, equipment and processes in their operational areas
  • ensuring workers, contractors, students and visitor are aware of their responsibilities and are provided with adequate information, instruction and training
  • establishing and maintaining a register and test schedule of plant, equipment, processes and work locations where testing and monitoring is required
  • ensuring legal requirements to undertake specific activities, perform work or operate equipment including the need for licences, certificates of competency, notification process, registration, approvals and other relevant requirements.

5.2The Risk Management Process

Under the Work Health and Safety(WHS) Regulations 2012, the University must manage risk to health and safety associated with management or control plant. This includes:

  • Identifying hazards
  • Assess risk if necessary
  • Control risk
  • Review control measures.

More information is available in theManaging the Risk of Plant in the Workplace Code of Practice.

5.2.1Identifying risk

Managers/Supervisors are to identify the risks associated with plant, including requirementsto:

  • Inspect the plant – Consider whether potential hazard from the plant, condition, suitability, location of the plant and any abnormal situation.
  • Review Safety Information – Information such as hazards, risk and control measures relating to plant in workplace.
  • Review Incident and Near Miss records and data.

5.2.2Assessing the risk

A risk assessment involves considering what could happen if someone is exposed to a hazard combined with the likelihood of it happening. Assessing the risk of plant operation and management include:

  • Identifying the potential impact of the risk
  • The likelihood of the risk to cause harm.

Each item of plant should have a Safe Work Procedure in place which is supported by a risk assessment and is reviewed in accordance with the Risk Assessment Procedure.

5.2.3Controlling the risk

Under the WHS regulation, the hierarchy of risk controlshould be used to control risk associated with plants.

The hierarchy of risk control method:

  • Elimination
  • Substitution
  • Isolation
  • Engineering controls
  • Administrative control
  • Personal protective equipment (PPE).

Combining control measures – In many cases, a combination of control will provide the best solution to control the risk.

5.2.4Maintaining and reviewing risk control measures

The Manager/Supervisormust apply control measures to ensure plant is:

  • Fit for purpose
  • Suitable for the nature and duration of the work, and
  • Installed, set up and used correctly

The Manager/Supervisormust review and as necessary revise control measures, including:

  • When the control measure is not effective in controlling the risk
  • Before a change at the workplace that is likely to give rise to a new or different health and safety risk that the control measure may not effectively control
  • If a new hazard or risk is identified
  • If the results of consultation indicate that a review is necessary, and
  • If a health and safety representative requests a review.

5.3Controlling Risks: From Purchase to Disposal

5.3.1Purchasing and Hiring plant

All purchasing of plant must be in accordance with thePurchasing Work Health and Safety Procedure and the University Procurement Policy. Any hazards that new plant will introduce into a workplace must be eliminated or controlled. In order to document this process the purchaser should complete a Pre-Purchase Checklist.

Before purchasing a plant, the Manager/Supervisor needs to check that it is suitable for the intended use including the environment it will be used in and the workers using it.

The Manager/Supervisor, before purchasing the plant, is required to:

  • Discuss the University needs with the plant supplier
  • Determine the hazards and risks associated with installation, commissioning, operation, inspection, maintenance, repair, transport, storage and dismantling of the plant.
  • Determine the control measures, special skills, and special conditions to operate the plant.
  • Check whether the plant includes some or all of the following characteristics:
  • contact with or access to dangerous parts is prevented
  • isof sturdy construction and is tamper proof
  • there is no obstructions to the plant operator
  • has a fail safe operation
  • is easy to inspect and maintain
  • does not introduce other hazards and
  • incorporates measures to minimise risk during use (e.g. low noise).

5.3.2Installation and commissioning of plant

The Manager/Supervisormust ensure that any new item of plant is commissioned by a competent person prior to use and that:

  • there is verification that the plant does not contain health and safety risks.
  • the person installing or commissioning the plant is a competent person, and is provided with all the information necessary to minimise risks to health and safety, and
  • the processes for the installation, construction and commissioning of plant include inspections that ensurethe risks are monitored.

If plant is imported from overseas a qualified electrician needs to inspect the plant to ensure that is conforms to AS 3000 (also known as Australian/New Zealand Wiring Rules) as far as it is relevant.

The Manager/Supervisor is required to ensure that:

  • Installation of a plant – Complies with relevant standards.
  • Consideration is given to the appropriate positioning of plant in the workplace.
  • Commissioning a plant – Performing adjustments, tests and inspections to ensureplant is working to design specifications.

5.3.3Instruction, training and supervision

Before plant is used in the workplace, Managers/Supervisors must provide workers, and other persons who are to use the plant, with the information, training, instruction or supervision that is necessary to protect them from risks arising from the use of the plant according to the Manufacturer’s instructions.

Any operator who is using, installing, commissioning, testing, maintaining, repairing, decommissioning, dismantling or disposing plant needs to be provided with instruction, training, an appropriate level of supervision and an assessment of the competency, ,so they can perform this task safely.

Induction and training requirements must beknown and understood for each item of plant and induction, training and competency records must be kept on file.

A Safe Work Procedure should be developed for each item of plant from a risk assessment assessed by a competent person with includesemergency instructions relating to that item of plant that is clearly displayed on or near the plant.

Managers/Supervisors should take action to correct any unsafe work practices associated with plant as soon as possible.

5.3.4Using plant in the workplace

Managers/Supervisors responsible for the management or control of plant must:

  • prevent unauthorised alterations to or interference with the plant
  • use the plant for the purpose for which it is designed
  • ensure all safety features, warning devices, guarding, operational controls, emergency stops are used in accordance with instructions and information provided
  • ensure operators of certain types of plant such as lift trucks or cranes, possess high risk work licenses that are contained in Schedule 3 of the Regulation.

5.3.5Altering plant

Any personintending to alter the design of the plant, change the way the plant is used or change a system of work associated with the plant,must carry out the risk management process again. The risk should be assessed by a competent person.

Before making alteration to the plant, the person should consult relevant parties to ensure relevant safety issues have been considered.

5.3.6Inspecting plant

Managers/Supervisors must ensure that maintenance, inspection, and if necessary testing, of plant is carried out by a competent person in accordance with manufacturer’s recommendation.

The Electrical Equipment – Inspection, Testing and Tagging Procedure and Workplace Inspection Procedureprovides guidance on determining plant inspection procedure in the workplace.

5.3.7Maintenance, repair and cleaning of plant

Plant must be maintained and repaired according to the manufacturer’s specifications or, in the absence of such specifications, in accordance with a competent person’s recommendations.

Maintenance planning activities should occur to ensure inspection requirements are implemented. Planning should consist of:

  • identifying the range of operational activities undertaken
  • ascertaining what testing, inspection and monitoring requirements are required as stated in Legislation, Australian standards, codes of practice and/or Manufacturers Operating Manuals, and the University Asset Management Policy and Asset Management Procedure
  • developing a schedule for inspection, testing and monitoring activities.

Following maintenance, all guarding must be replaced prior to start-up of plant.

Damaged plant should be withdrawn from service until any risks to health and safety have been controlled.

5.3.8Storing plant

Managers/Supervisors mustensure that plant not in use is left in a state that does not create a risk to the health or safety of any person.

5.3.9Decommissioning, dismantling and disposing of plant

Managers/Supervisors are required to ensure that:

  • Plant is not decommissioned or dismantled unless it can be carried out without risks to health and safety.
  • The person who decommissions or dismantles the plant is a competent person, and is provided with all available information necessary to eliminate, or minimise risks to health and safety, and
  • The processes associated with the decommissioning and dismantling include inspections to ensure that risks associated with these activities are monitored.

The Managing Risk of Plants in the Workplace Code of Practice provides guidance in the process of decommissioning and dismantling the plant using specific control measures.

5.3.10Guarding plant and Operator controls

The Managing Risk of Plants in the Workplace Code of Practiceand ss 208 – 210A of the WHS Regulation provides a guide in using a guard when operating plants or managing risk.

5.3.11Emergency stops

WHS Regulation, s 211 requires the University to ensurean emergency stop control are:

  • The stop control is prominent, clearly and durably marked and immediately accessible to each operator of the plant
  • Any handle, bar or push button associated with the stop control are coloured red, and
  • The stop control cannot be adversely affected by electrical or electronic circuit malfunction.

Emergency stop devices should not be the only method of controlling risks. They should be designed as a back-up to other control measures.

5.3.12Warning devices

WHS Regulation, ss 212 and 215 requires the Universityto ensure that an emergency warning device is positioned on the plant to ensure that the warning device will work to best effect. The University must alsoensure that the plant has a warning device that will warn persons who may be at risk from the movement of the plant, i.e. pedestrians.

Information of list of warning devices that be fitted to moving and non-moving plant can be acquired at the Managing Risk of Plants in the Workplace Code of Practice.

5.3.13Isolation of energy sources

An isolation procedure is a set of predetermined steps that should be followed when workers are required to perform tasks such as maintenance, repair, installation and cleaning of plant. The University requires the most effective isolation procedure which is the lock out process.

Isolation procedures involve the isolation of all forms of potentially hazardous energy so that the plant does not move or start up accidentally. Isolation of plant also ensures that entry to a restricted area is controlled while the specific task is being carried out.

The Plant Isolation – Lock out/Tag out Procedure should be implemented and Lock Out Tag Out (LOTO) equipment available. Following LOTO all plant and equipment should be inspected by a competent person before it is returned to service.

5.4Plant registration

Certain items of plant and types of plant designs must be registered with the Regulator WorkSafe Tasmania or State equivalent. A list of registrable plant is provided at Managing Risk of Plants in the Workplace Code of Practice- Appendix A.

These include boilers, pressure vessels, tower cranes including self-erecting tower cranes, lifts/ escalator/moving walkways, mobile elevated work platform, amusement device, concrete placing boom or mobile crane.

Registrable plant must be:

  • Design registered before it is supplied
  • Item registered before it is used
  • Meet compliance requirements such as valid high risk license operators and maintenance schedules.

Please contactISDfor further information on registering high risk plant.

5.5Keeping records

WHS Regulation, s 237 requires the University to keep a record for plant that requires design or item registration including records of all tests, inspections, maintenance, commissioning, decommissioning, dismantling and alterations of the plant.

The records must be available for inspection under the WHS Act and be made available to any person to whom the person relinquishes control of the plant, for example if you sell the plant, those records should be transferred to the person who purchased the plant.

Keeping records of the risk management process demonstrates potential compliance with the WHS Act and Regulations. It also helps when undertaking subsequent risk assessments.

6Responsibilities

Managers/Supervisors / Managers/Supervisors need to ensure that workers are able to undertake plant operation safely by implementing this Minimum Standard in their area of responsibility. Where a worker is required to supervise a plant operation, the Manager/Supervisor is responsible for ensuring that delegated safety responsibilities are fulfilled and that appropriate supervision is provided. Managers/Supervisors must also ensure that appropriate records relating to managing the Plant and training records are kept.
Officers / Officers need to ensure that where workers are required to undertake plant operation or manage risks associated with plant, they do so in accordance with this Minimum Standard. They are to ensure that Organisational Unit specific guidelines are developed where necessary, and that they are consistent with the information contained in this document.
Workers / Are to report all hazards associated with plant, complete risk assessments and implementing corrective actions to eliminate or control the risks associated with hazards and ensure they are adequately or appropriately trained in the safe operation of the plant they are required to use.
WHS Unit / Monitors the University's compliance with this Minimum Standard, and provides advice/guidance to Organisational Units. Approves any exemptions to meeting Minimum Standard requirements
Personnel Conducting Inspection, Testing and Monitoring / Are competent to complete inspection and testing requirements. The majority of these requirements are detailed in Legislation, Codes of Practice or Australian Standards. Conduct inspecting and testing procedures in accordance with any Legislative, Code of Practice or Australian Standard requirements.

7Glossary