Equipment and Machinery Guarding

Safety Standard
Document no: BSL/SS/GEN-09 Version: 0.0,
Issue Date: 29th September’ 2018

Responsibility Prepared By Reviewed By Authorized By

Name B BEHERA A PANDA R K GUREJA

Designation Sr. GM, Coke Oven-2 AVP, Safety VP, Shared Services
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Change Authorization
Document Number BSL/SS/GEN-09
Apex Safety Standard Sub-committee
Overall Process Owner
Process Change Authorization Standard Owner -
BSL
To be Reviewed By Standard Owner –
BSL
Periodicity of Review of this Document Three years

Version Control History

Revision
Ver Date Version Prepared Authorized
Summary
. Details by by
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Table of Contents:
Page
Number Subject
Number
1.0 Purpose 4
2.0 References 4
3.0 Applicability 4
4.0 Responsibility 4
5.0 Associated Hazards 4
6.0 Definitions 4
7.0 Procedure 4
7.1 Classification of Safeguarding of the Equipment 4
7.2 Guarding can again be classified according to the nature of the job 5
7.3 Materials for safe guard 5
7.4 Construction of the safe Guard 5
7.5 Equipment 6
7.5.1 Belt and pulley 6
7.5.2 Chain and Sprockets 8
7.5.3 Couplings– Input/output shafts 8
7.5.4 Flywheels/Bull gears/ open Gears 8
7.5.5 Tail end of belt conveyor 8
7.5.6 Brakes and clutches 8
7.5.7 Other projected parts 9
7.5.8 Conveyor gravity take-up unit area 9
7.5.9 Drive lay-shaft with couplings 9
7.5.10 Crane rope pulley blocks and sheaves 9
7.5.11 Pump stuffing box 10
7.6 At working site 10
7.6.1 Lubrication 10
7.6.2 Online cleaning / Condition Monitoring/ Sampling 10
7.7 Accessory equipment 11
7.8 Training 11
7.9 Safeguarding Checklist 12
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1.0 Purpose: The standard provides information regarding safeguarding of equipment and the material
and construction of the guards. Section 6 describes safeguarding based on classification of equipment.

2.0 Reference: SS/ GEN -09, SS/ ENG–18, Workers Compensation Board (BC).

3.0 Applicability: This standard is applicable to all locations of TATA STEEL LTD in India

4.0 Responsibility: Responsibility for implementation of this standard lies with all executing
departments like Engg. & Projects, Engg. Services, Maintenance Departments and Contractors,
Consultants.

5.0 Associated Hazards: Injury due to rotating equipment, components flying out due to centrifugal
force, body parts like hand/ finger or clothing getting caught in the rotating component.

6.0 Definitions:

6.1 Competent person - One who is capable of identifying existing and predictable hazards in the
surroundings or working conditions which are unsanitary, hazardous, or dangerous to people, and who
has authorization to take prompt, corrective measures to eliminate them.

6.2 Qualified person - One who, by possession of a recognized degree, certificate, or professional
standing, or who by extensive knowledge, training, and experience, has successfully demonstrated his
or her ability to solve or resolve problems related to the subject matter, the work, or the project.

7.0 Procedure:

7.1 Safe guarding of the equipment can be classified in the following ways:

7.1.1 Safe guarding of mechanical power transmission equipment

• Belt and pulley

• Chain and sprocket
• Couplings- Input/ output shafts
• Flywheels/ Bull gears/ Open gears
• Tail end of belt conveyor
• Brakes and clutches.
• Other projected parts.

7.1.2 Safeguarding of equipment at working site

 Safe guarding of equipment during lubrication

 Safe guarding of equipment while online cleaning.
 Safe guarding of equipment while condition monitoring and sampling.

7.1.3 Safe guarding of accessory equipment:

• Exhaust fan, man cooler fan, pedestal fan, grinders
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7.2 Guarding can again be classified according to the nature of the job:

7.2.1 Temporary safeguarding:

 Where jobs are carried out onetime near the rotating or projected part of
equipment (described in section 6.1).
 The guards must be designed that it can easily be refitted. The large guards must be
made from a number of sections and provide handles and locating points.
 The safety guard shall be in pieces of convenient size, bolted/ hooked to fix the
structure for easy removal during maintenance/ condition monitoring.

7.2.2 Permanent safeguarding:

 Where regular jobs are carried out near the rotating or projected part of
equipment (described in section 6.1).

7.2.3 Safe Guarding of equipment which can release toxic gases and liquids and hot or
extreme cold liquid:

 During operation of the equipment, it accidently releases toxic gas, liquids or hot or
extreme cold liquid or gas and high pressure liquid or gas. Such equipment should
be guarded up to the likely affected area in case such accidental incidence occurs.


 If the process demands movement of people to such locations, the area should be
restricted for any movement with proper access control as per local SOP.

7.3 Materials for safe guard: Wire mesh, Metal sheet, and transparent plastic sheet.

7.4 Construction of safeguard:

7.4.1 The choice of material of construction is largely a matter of local preference based upon operating
conditions, types of guards already installed.

7.4.2 Frame work / Railing of the safeguard: - Angles/ Flat, hollow structure or pipe can be used. The frame
should be so designed such that it can take the vibration of the equipment and should be securely
fastened.

7.4.3 Filler Material: - Wire mesh, perforated or solid sheet metal, high strength plastic. Should be strong
enough not to break or disintegrate under vibration and atmospheric conditions.

7.4.4 If guards are located out door, painted or galvanized steel sheets to be used.

7.4.5 Guards furnished with purchased equipment are desirable if they meet the general requirements of
this standard.

7.4.6 Filler Dimensions- Wire mesh (Refer Fig 1)

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‘a ‘ is the sides of square in wire mesh - 12 to 20 mm (1/2 in and ¾ in).

‘b’ is the minimum clearance between guard and machinery - 120mm (4 ¾ in) . The wire diameter should be
between 1.5mm to 3mm

Metal, transparent plastic sheet (Refer Fig 2)

Sheet thickness - 2 mm to 5 mm

Minimum clearance between safe guard and rotating machine- 120 mm

7.5 Equipment:

7.5.1 Belt and pulley:

7.5.1.1 All power transmission belts, any part of which is 8 feet or less from the floor or working
platform, shall be guarded fully except slow moving (less than 250 ft per minute) belts of the
following specification: flat belts 1 inch or less in width; flat belts 2 inches or less in width, which
are free from metal lacings or fasteners; round belts one–half inch or less in diameter; and
single– strand V–belts, 13/32–inch wide or less.

7.5.1.2 Horizontal overhead belts, 7 feet or more above the floor or platform, shall be guarded
for their entire length under the following conditions.

i. If located over passageways or work places and traveling 1800 feet or more per minute.
ii. If centre–to–centre distance between pulleys is 10 feet or more.
iii. If belt is 8 inches or more in width.
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7.5.1.3 Vertical and inclined belts shall be enclosed in a manner similar to horizontal belts.

7.5.1.4 Overhead belts–belt drives are governed by the same rules as overhead horizontal

7.5.1.5 Metallic belt lacing or fasteners shall not be used in areas containing explosives or
Flammable vapors.

Figure: 3

7.5.1.6 Pulleys, any part of which are 8 feet or less from the floor or working platform, shall be
caged.

7.5.1.7 Unless the distance to the nearest fixed pulley, clutch, or hanger exceeds the width of the
belt used, a guide shall be provided to prevent the belt from leaving the pulley on the side where
insufficient clearance exists.

7.5.1.8 Unless the distance to the nearest fixed pulley, clutch, or hanger exceeds the width of the
belt used, a guide shall be provided to prevent the belt from leaving the pulley on the side where
insufficient clearance exists.

7.5.1.9 Where separate pulley guards are used under conditions and the belt does not require
guarding, the guard should enclose the pulley so as to protect the run– in point of the belt. The
guard should extend slightly higher than the top of the pulley, the belt running through a slot or
narrow opening which would not permit the hand to be drawn into the nip–point.

7.5.2 Chain and Sprockets: The safeguarding is similar as explained in section 7.5.1.1 to 7.5.1.5.

7.5.3 Couplings– Input/output shafts: Couplings mounted at input or output shaft of the machine must be
guarded by a stationery guard as explained in section 7.4.
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7.5.4 Flywheels/Bull gears/ open Gears:

7.5.4.1 Guards shall be provided on flywheel/ bull gear/ open gear as explained in section 7.4

7.5.4.2 When the upper rim of flywheel / bull gear/ open gear protrudes through a working floor it shall
be enclosed entirely or surrounded by a guardrail and toe board.

7.5.4.3 When flywheel/ bull gear/ open gear extends into pit or within 12 inches of floor standard toe
board shall be provided.

7.5.5 Tail end of belt conveyor: The tail end of a belt conveyor having rotating pulley must be guarded as
explained in SS/ENGG 18

Figure 5: Guarding of tail end pulley

7.5.6 Brakes and clutches: Brakes and clutches mounted at input or output shaft of the machine must be
guarded by a stationery guard as explained in section 7.4.

Figure 6 Figure 7
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7.5.7 Other projected parts :

This includes (Refer Figure 7)--

• Protruded parts of stationery structures in the walkway/ nearby the working area,
• Uncoupled shaft of gearbox / pulleys/ rolls.

The safeguard shall be provided as explained in section 7.4.

7.5.8 Conveyor gravity take-up unit area:

Cover the area 1 feet extra away from each side of specified area of GTU with steel net height 5 feet. Each side
to be connected with steel frame and net panels for easy removal during maintenance job.

7.5.9 Drive lay-shaft with couplings:

All drive lay-shaft is to be covered with steel half pipe or fabricated cover with clearance of 2 inch in all side. It
is to be bolted with bearing base area for easy removal during maintenance time.

7.5.10 Crane rope pulley blocks and sheaves:

To be covered with proper hood and well fixing arrangement with bolt. Protection guards for rope drive area.
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7.5.11 Pump stuffing box:

Pump stuffing box area to be covered with fabricated steel plate or half cut pipe as per required size to avoid
hazardous chemical spaying outside in case of seal failure or any circumstances of chemical leakage from
stuffing box.

7.6 At working site:

7.6.1 Lubrication: If the lubrication point is near to the rotating equipment the
safeguard and the lubrication facility shall be given as follows:

7.6.1.1 The guards must be designed to reduce the need to remove them. For
example provide access to tracking mechanisms in figure 8: (A) and greasing
points (B).

Figure: 8 Lubrication points

7.6.2 Online cleaning / Condition Monitoring/ Sampling:

7.6.2.1 During online cleaning/ condition monitoring / sampling the rotating or projected part
of equipment must be guarded.

7.6.2.2 The difficulties associated with frequent removal of guards and the continual stopping
for cleaning purposes may be overcome by using hinged guards which allow access.

Figure: 9 guarding at position of condition monitoring & sampling

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7.7 Accessory equipment:

7.7.1 Grinders:

The associated risk of bench grinders, pedestal grinders, and portable grinder is
fragmentation of an abrasive wheel.
The main objective of safeguarding is to contain pieces of the abrasive wheel if a rupture
occurs.
The maximum wheel exposures for guards on two types of abrasive equipment: bench
and pedestal grinders (90° exposure) and hand -held angle grinders (180° exposure) is
illustrated in the figure10. The protective hood of a portable grinder must cover at least
120° of the wheel periphery.

7.7.2 The Fan must be guarded by a galvanized wire mesh. The dimension of wire mesh should be between 4 to
8 mm and minimum clearance between fan and guard should be at least 15 mm. Khas-Khas curtains, clothes
etc. should not be placed over the fan guards. Water for cooling should not be used near at the fan.

7.8 Training

 All personnel whose job requires working close to rotating equipment shall be trained
by a competent person prior to starting the job.

 Safety precautions specific to the equipment in which the person is supposed to work
should be explained to him a competent person prior to starting the job.


 A hazards assessment by working unit or function is required for the area

concerned.
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7.9 Safeguarding Checklist

The checklist attached below is a guideline for safeguarding

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Annexure: -1

Item Item Code No. Specification

Square Hollow
38X38X3.2 mm
Section
Square Hollow
25X25X3.2 mm
Section
Square Hollow
49.5X49.5X3.6 mm
Section
Acralic Transparent 130
Plastic Sheet mmX5mmX10m
Flat MS Flat 25X3mm

Angle MS25X25X3mm

Temporary entry or opening / removal of barrication:

If the process demands that a person will have to temporarily remove the barrication and
enter into a forbidden area the six direction risk must be assessed before entering such area and
proper personal protective equipment such as full body harness, gas detectors, oxygen masks,
body and face protection devices whatever applicable must be used before entering such area.
The person should remain there for the shortest possible time in such area.
The area should be re-barricaded temporarily so no other person other than the authorized
person can enter the area.