Power & Water Utility Company for Jubail Document ID No : MSSM-1-SF-002

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32. MACHINE GUARDING

1. PURPOSE
To ensure that the safety of employees is not jeopardized when using machinery by providing guarding
appropriate to the risks.

2. SCOPE
This procedure applies to the use of machines that may put employees or others at risk of harm from
moving or harmful parts of the machine whilst using them. This includes using Marafiq owned and
controlled machinery or any other machinery that they may be required to use.

3. DEFINITIONS & ACRONYMS

3.1 Acronyms:

PPE – Personal protective equipment

3.2 Definition

Guard – A barrier or system that prevents any part of the operator coming into contact with a
moving part of machinery.

Danger Zone – Area within which a person can get a part of the body caught between moving
parts of the machine, moving and stationary parts of the machine, or material and moving parts
of the machine.

Nip Points – Formed between two components or two or more parallel shafts, whether in
contact or apart or rotating in opposite directions.

Moving machinery parts: Parts which are rotating, sliding, reciprocating or having combination of
these movements (Examples: drive belts, chain and sprocket drives, V belts, shafts, flywheels,
cooling fans and any other rotating equipment)

Use – includes normal operation; maintenance; cleaning and adjusting.

4. RESPONSIBILITIES

Department Managers
Department Managers shall be responsible for ensuring that any machinery brought into the company
will be suitable, as described in this and other procedures, for the task to be carried out and the
environment in which it will be used. Additionally, they shall be responsible for ensuring that resources
are made available for the training of personnel and the maintenance of machinery.

Superintendents and Supervisors

Superintendents and Supervisors will be responsible for ensuring that all personnel who use the
machinery are properly trained and that the machines are maintained in line with a planned

PROPRIETARY NOTICE IMPORTANT

THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO MARAFIQ. ANY DISCLOSURE OR USE ONLY DOCUMENT WITH STAMPS IS CONSIDERED OFFICIAL.
IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY MARAFIQ.
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maintenance program. They shall also be responsible for ensuring that regular inspections of
machinery are carried out.

Employees
Employees, including operators and maintenance staff, shall work in accordance with the training,
information and instruction provided to them. They shall also be responsible for reporting any defects or
shortcomings that they identify whilst using the machinery.

5. PROCEDURE CHART

Machinery to be used

Step 1
Ensure all machinery is suitable for
the task being undertaken

Mechanical Hazards Step 2 Non – Mechanical Hazards

Identify hazards associated with the
machine

Step 3 Step 4
Determine suitable guards and Determine suitable controls to
protective devices following protect against identified non-
Hierarchy of Safeguarding mechanical hazards

Step 5
Ensure all users are given proper
training and information on hazards
and controls, inspect regularly

PROPRIETARY NOTICE IMPORTANT

THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO MARAFIQ. ANY DISCLOSURE OR USE ONLY DOCUMENT WITH STAMPS IS CONSIDERED OFFICIAL.
IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY MARAFIQ.
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6. RELATED DOCUMENTS
Procedure – OHS Inspection
Procedure – Risk Assessment
Procedure – Training, Information, Instruction
Form – Machine Safety Inspection
Guidance – Machine Guarding

7. 7.0 GUIDANCE – Procedure

Step 1 – Ensure all machinery is suitable for the task being undertaken

All machinery must be:

 Suitable for its intended purpose i.e. for the process and the environment it is to be used in.
(Examples: The choice of pneumatically or hydraulically powered machinery in wet or
flammable atmospheres should be considered in place of electric tools. The use of petrol/diesel
engine generator which is discharging exhaust fumes should not be allowed in a confined space
or buildings)
 Used in accordance with the manufacturer’s specifications and instructions. Operated or
maintained by trained, competent and authorized personnel who have been provided with
relevant health & safety information and written instructions on its hazards and safe use.
 Maintained in good working condition to ensure the effectiveness of the machine.

Step 2 – Identify hazards associated with the machine

Mechanical Hazards
All dangerous moving machinery parts must be guarded in order to prevent a person from making
accidental contact and getting injured due to the following:

 Entanglement due to things such as long hair or loose clothing wrapping around rotating
machinery e.g. power take off couplings, spindles, screw drives, shafts.
 Friction and abrasion caused by contact with moving parts of machinery, particularly those with
a rough or abrasive surface. A common example would be contact with a grinding wheel.
 Cutting caused by body parts coming into contact with cutting blades, circular saws, etc.
 Shearing, where a body part, such as a finger, gets caught between two machinery parts such
as the blade and bed of a guillotine.
 Stabbing and Puncture where the body may be penetrated by flying objects such as a burst
abrasive wheel or from contact with a sharp pointed piece of machinery such as a drill bit.
 Impact is simply being struck by a moving piece of machinery. Probably the most common
example is being struck by a vehicle.
 Crushing between two parts, in a press for example.
 Drawing-in between two meshing gears, rollers, drive wheels and belts. Known as nips, these
hazards must be identified as they can be the cause of very serious injuries.

Non-mechanical hazards

PROPRIETARY NOTICE IMPORTANT

THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO MARAFIQ. ANY DISCLOSURE OR USE
IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY MARAFIQ. Only document with stamps are considered official.
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Operators and others should be aware of hazards arising from the way that the machine is
powered and anything produced as a result of the machine operating. Common non-mechanical
hazards associated with the use of machines include:

 Electric shock due to contact with live electrical components.

 Fire and explosion due to use of flammable substances such as petrol; or caused by
overheating because of lack of maintenance.
 Noise and vibration caused by lack of maintenance and poor selection of machines.
 Heat and light given off from activities such as welding.
 Smoke, dust and fumes produced from running engines or cutting processes.
In addition, ergonomic issues such as space and manual handling should be considered.

Step 3 – Determine suitable guards and protective devices to protect against mechanical hazards
following the Hierarchy of Safeguarding

Hierarchy of Safeguarding

1. Provision of fixed guards

Preferably, fixed enclosure guards which form a barrier between the operator and the dangerous parts
of the machine should be installed. Fixed guards are the most appropriate where frequent access to the
moving parts is not required. The fixed guard should be:
 Fitted is such a way that a tool is required to remove it.
 Constructed of material which is strong enough to prevent access to the dangerous parts.
 Properly maintained and fitted.

2. Other types of guard and protective devices

This may include the use of interlock guards; adjustable guards and trip devices.
Interlock guards prevent the starting of the machine when the guard is open and stop the machine
when the guard is opened.
Adjustable guards allow the operator to alter the working clearance to cater for different sizes of work.
These are commonly used on machines that cut and need an exposed blade.
Protective devices – such as trip controls, wire cable, presence sensing device (photoelectric),
emergency stop switch, etc. – will:
 Stop the machine if a body part is inadvertently placed in the danger area; and/or
 Restrain or withdraw the operator's hands from the danger area during operation

3. Use of protective appliances

Appliances, such as push sticks; jigs; vices; clamps etc. are used to hold and guide work thus removing
the operators’ hands from the danger area. They are commonly used in conjunction with circular saws
and pedestal drills.

PROPRIETARY NOTICE IMPORTANT

THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO MARAFIQ. ANY DISCLOSURE OR USE
IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY MARAFIQ. Only document with stamps are considered official.
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These should not be used in preference to measures in 1 and 2 above but can add extra safeguarding
as part of a good control strategy.

4. Information, instruction, training and supervision

All personnel who are expected to use machinery should be given information and training on the
hazards and risks associated with the machine the control measures in place to protect the user and
others. Supervisors should ensure that the machines are used correctly.

Other measures

In addition to the control hierarchy mentioned above, additional measures may be considered. They
include:

 Full automation. This is designed in such a way that there is no exposure of human beings to the
machine. This can be a particularly expensive alternative and may not be a reasonable option
 Fitting of an emergency stop mechanism. The actuating button, bar or lever should be easily
accessible from the normal work position.
 Use of signs and notices. This helps to raise and maintain awareness of hazards associated with
the machine.
 Regular inspections. Designed to identify any maintenance issues and to ensure that guards are in
place and working. (Example of Inspection Checklist in the guidance to this procedure.)

Step 4 – Determine suitable controls to protect against identified non-mechanical hazards

Having identified the non-mechanical hazards associated with the use of the machine(s), the application of
sound control measures based on the principles of prevention should reduce the risks to an acceptable
level. The main considerations are:

 Selection of suitable machinery.

 Ensuring that the machine is properly used by trained, competent personnel.
 Ensuring that the machine is maintained in accordance with a planned maintenance process.
 Reduction of risk at source; such as local exhaust ventilation for any dust or fumes that are
produced.
 Isolation of the risks from users by means of barriers, screens etc.
 Provision, and wearing, of suitable Personal Protective Equipment, where necessary, to take
account of any residual risk.
 Good management and supervision to ensure that the above controls are implemented and
maintained.

Step 5 – Ensure all users are given proper training and information on hazards and controls and inspect
regularly.

PROPRIETARY NOTICE IMPORTANT

THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO MARAFIQ. ANY DISCLOSURE OR USE
IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY MARAFIQ. Only document with stamps are considered official.
 Power & Water Utility Company for Jubail and Document ID No : MSSM-1-SF-002

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Once suitable control measures have been identified and agreed, an important part of the implementation
of these measures is to ensure that everybody who may be involved with using the machine is given
thorough information and training on:
 How to use the machine properly.
 The hazards associated with the machine.
 The control measures in place and how to use them.
This should be backed up with good supervision to ensure that these measures are adhered to.

All machines must be inspected regularly to ensure the control measures to prevent harm remain effective.
Inspections should be documented and records of inspection retained to demonstrate regular inspection
and corrective action.

PROPRIETARY NOTICE IMPORTANT

THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO MARAFIQ. ANY DISCLOSURE OR USE
IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY MARAFIQ. Only document with stamps are considered official.