TE-MSC Safety Day

Mechanical and Handling Hazards

F. Savary
Part I: Mechanical hazards

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Definition
• A mechanical hazard is any
hazard involving a machine or
process
• Are essentially due to machine,
components of the machine,
moving parts of the machine,
or any other source, which can
injure a person
• Compressed gases or liquids can
Types of mechanical injuries
also be considered a mechanical
hazard Cut Laceration Bruises

Puncture Crush Bone

Hematomas

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 Machining* operations
*Or more generally, operations on/with machinery/tools
• Conventional and CNC machine tools
… but also folding presses, rolling
machines, and cabling machines are
other types
• There are more special machines, e.g.
M-line orbital cutting machines (LS1)
and bus bar surfacing, grinding
machines, sawing, …
• Against metal chips, burrs, powders,
lubricants, cleaning agents, solvents:
• Goggles, gloves

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Some materials are more aggressive
• Fiberglass and composite materials
require particular precautions
• Always wear respirator/face mask,
and goggles

• Many resins are inflammable or contain additives

that are inflammable, so be careful with heat sources
• Many materials used in fiberglass work are corrosive, or
have some undesirable effect on the skin (irritant), so
protect your skin/eyes … again goggles and gloves!

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Heavy loads may fall on the floor!
• … and worst, on your foot!

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Welding, soldering, brazing
• Personal protection (the welder)
• Burns (adapted cloth, gloves), arc flash - “coup d’arc” (protect your face/eyes with
a welding mask)
• Protection of personnel working at the vicinity of a welding area (not
the welder)
• Use curtains to surround the welding area
• Soldering, e.g. when using tin lead alloy (soldering of the shunts)
• Analyses of fumes, in collaboration with HSE, have shown no trace of Pb, i.e. no
need of a specific filter for this. However, a filter was used to prevent other hazards
due to traces of rosin and alcohol

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Welding press for dipole shells, 1
• On top of obvious welding related hazards
• Mechanical hazards due to the necessity for
the welder to watch carefully the weld pool
during welding, …
in a small space

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Welding press for dipole shells, 2
emergency cable pull switch

Help is recommended in certain

circumstances … allocate sufficient
resources
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Hydraulic and pneumatic systems, 1

Collaring press:
Up to 375 MN over 15 m!
High pressure up to 700 bar

Hydraulic group of the

welding press:
Up to 162 MN over 16 m
High pressure up to 550 bar

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Hydraulic and pneumatic systems, 2
• High pressure fluids hazards, hydraulically and
pneumatically driven tools hazards
• Crushing, high pressure / hot fluid leaks / jets

• High pressure oil easily punctures skin causing

serious injury, gangrene or death
• If injured, seek emergency medical help.
Immediate surgery is required to remove oil
• Do not use finger or skin to check for leaks
• Lower load or relieve hydraulic pressure before
loosening fittings
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Real case: pressure test
• When: March 2007
• Where: LHC tunnel
• Need: verify/accept triplets after
installation in the tunnel
• Action: carry out pressure test
• Incident: due to movement of one of the
cold masses, rupture of a helium piping with
strong detonation
• Consequence: 2 of the 7 persons who witnessed
the test (even if at 25 m of the incident) presented
signs of hearing loss (that disappeared after some
time). Only one of the seven was wearing hearing
protection

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• Machine conformity – Mise en conformité des machines
• To be checked with EN-MME, Emmanuel Ravry / Alain Stalder
• Safety Form M-4-0-2 - Workshop machine tool - Authorization of use
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For new and special machines
• For example, a 6.5 m long reaction furnace currently in assembly in
B180
• Risk assessment file shall be developed by the manufacturer
• There are guidelines available at:
• https://edms.cern.ch/document/1114042/3: Safety Guideline on risk assessment
• https://edms.cern.ch/document/1114759/3: Safety Tool for risk assessment
• https://edms.cern.ch/document/1218312/1: List of generic hazards typically present in
workshops

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Safety form – Risk assessment form
RISK ASSESSMENT FORM OHS-0-0-5
Department/Group:
Location:
TE/MSC-LMF
Bâtiment 180
Template EDMS No.: 1175316

Assessment done by:

EDMS:
Life Cycle
Description of the equipment: Production
Date: 31 July 2012
Risk with current control measures and/or detection means

FAILURE MODE, EFFECTS AND CRITICALITY ANALYSIS (FMECA)

Potential effect(s) Control measure(s) S
ID Component Function(s) Potential failure mode(s) Potential cause(s) Detection mean(s) P R Risk Level Further measure(s) required
Local effect(s) End effect(s) Provision measure(s) Compensating measure(s) People Environment Property Operational

Item 1:
Actionne la mise en rotation
Pas de mise en rotation de la Contrôler le branchement électrique Contrôle de l'équipement Utiliser le matériel électrique Acceptable risk: no actions need to be Fiche d'instructions de la machine de
Moteur METABO BE1100 * de la machine orbitale de Le moteur ne fonctionne pas Absence d'alimentation Activité stoppée 2 A A A A A2
machine du moteur avant utilisation de réserve taken. découpe
découpe

* cet équipement commerciale

est doté en origine d'une
certification CE, ici on considère Non respect de la procédure de changement des Contrôle du sens de Moderate risk: actions are recommended Formation; procédures LS1. 3.1
L'outil tourne dans le mauvais sens Mauvais réglage du moteur Risque de casse de l'outil Contrôle visuel Procédure et formation 3 B A B A B3
les risques inhérents à son outils rotation avant utilisation to reduce the risk. découpe des manchettes M
utilisation spécifique dans
l'assemblage en objet.

Utilisation d'un nouveau moteur à sa

Contrôle du réglage de la Moderate risk: actions are recommended
Vitesse de rotation trop importante Mauvais réglage du moteur Mauvais réglage du moteur Risque de casse de l'outil Contrôle visuel Procédure et formation 3 B A B A B3 vitessse maximale.
vitesse avant utilisation to reduce the risk.

Utilisation de protections auditives

Ne pas utiliser la protection auditive (Niveau sonore Non respect de la procédure durant le Utilisation EPI, respect des Moderate risk: actions are recommended
Dommage auditif Dommage auditif Contrôle médical Procédure et formation 3 B A A A B3 Procédures LS1. 3.1 Découpe
85 à 90 dB) fonctionnement de la machine procédures to reduce the risk.
manchette M
Item 2:
Permettent la mise en rotation Utilisation de Chaussures de sécurité
Coquille de découpe et cage Utilisation EPI, respect des Moderate risk: actions are recommended
et l'avance de l'outil de Chute pendant la manipulation Mauvaise manutention par l'opérateur dommage corporel Activité stoppée, dommage corporel Contrôle visuel Procédure et formation 3 B A B B B3 Procédures LS1. 3.1 Découpe
d'entrainement procédures to reduce the risk.
découpe manchette M

L'opérateur doit faire

Intrusion d'un personne extérieuredans la zone de Moderate risk: actions are recommended Formation; procédures LS1. 3.1
Blessure d'un personne extérieure à l'activité dommage corporel Activité stoppée, dommage corporel Contrôle médical respecter sa zone de Procédure et formation 3 B A A A B3
découpe. to reduce the risk. découpe des manchettes M
travail

Utilisation de lunette de protection

Utilisation EPI, respect des Moderate risk: actions are recommended
Projection de copeaux Risque inhérente à la l'activité coupure dommage corporel Activité stoppée, dommage corporel Contrôle médical Procédure et formation 3 B A A A B3 Procédures LS1. 3.1 Découpe
procédures to reduce the risk.
manchette M

Utilisation de lunette de protection

Utilisation EPI, respect des Moderate risk: actions are recommended
La plaquette casse Risque inhérent à la l'activité Plaquette à changer Activité stoppée, dommage corporel Contrôle médical Procédure et formation 3 B A A A B3 Procédures LS1. 3.1 Découpe
procédures to reduce the risk.
manchette M

Insister sur la mise en place du bras de

Rotation le l'ensemble de la Activité stoppéee, dommage Moderate risk: actions are recommended maintient de la machine
La machine se bloque L'outil se bloque dans la piéce Contrôle médical Procédure et formation Procédure et formation 3 B A B B B3
machine corporel to reduce the risk. Procédures LS1. 3.1 Découpe
manchette M

Insister sur la mise en place du bras de

Non respect de la procédure de la part de Rotation le l'ensemble de la Moderate risk: actions are recommended maintient de la machine
L'outil se bloque dans la piéce Activité stoppée, dommage corporel Contrôle médical Procédure et formation Procédure et formation 3 B A B A B3
l'opérateur machine to reduce the risk. Procédures LS1. 3.1 Découpe
manchette M

Un carter de protection de l'outil opposé

Controle de la mise en
Entrainement de la main de l'opérateur par le porte L'opérateur pose la main sur l'outil opposé à la coupure dommage corporel Activité stoppée, dommage corporel Unacceptable risk: immediate actions are doit être fabriqué
Contrôle médical place du capot de Procédure et formation 3 C A B B C3
outil coupe définitif definitif necessary to reduce the risk promptly. Procédures LS1. 3.1 Découpe
protection
manchette M

Un carter de protection de l'outil opposé

Usinage des deux soudures d'une même Non respect de la procédure durant le L'Attention de l'opérateur est Dommage sur la machine, Moderate risk: actions are recommended doit être fabriqué
Contrôle médical Procédure et formation Procédure et formation 3 B A B B B3
manchette en même temps fonctionnement de la machine portée sur deux endroits dommage corporel to reduce the risk. Procédures LS1. 3.1 Découpe
manchette M

Relacher la commande du moteurdés

Mauvais serrage des demi coquilles, pignon ou Risque de casse de la Moderate risk: actions are recommended les premières vibrations.
Vibration de la machine de découpe Activité stoppée, dommage corporel Contrôle visuel Procédure et formation Procédure et formation 2 B A B A B2
engrenage défectueux machine to reduce the risk. Procédures LS1. 3.1 Découpe
manchette M

Insister sur le fait que le moteur doit être

Mise en rotation de l'engrenage ou des outils lors de 18/9/2014

Non respect de la procédure durant le coupure dommage corporel Activité stoppée, dommage corporel
Contrôle médical
Contrôle du Mechanical and Handling Hazards
débranchement du moteur Procédure et formation 3 B A B A B3
Moderate risk: actions are recommended
plaquettes. 15
débranché lors du changement des

Fiche d'instructions de la machine de

la mise en place de la cage d'entrainement fonctionnement de la machine définitif definitif to reduce the risk.
avant mise en place découpe
Procédures LS1. 3.1 Découpe
manchette M
See next presentation by John Pedersen

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Part II: Handling hazards

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Definition
• Manual handling of loads (MHL) and manual
material handling (MMH) involve the use of the
human body to lift, lower, fill, empty, or carry loads
• When performed incorrectly or excessively, these tasks may expose
workers to physical risk factors, fatigue, and injury
• A variety of MMH techniques and tools
exist to alleviate these potential problems
• Forklifts, overhead cranes, lifting girders,
SpanSet® slings, …

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Manual handling and lifting
• There are legal limits, depending on the age/sex, but also the distance
and the characteristics of the task (articles R. 4541-1 à R. 4541-9 du code
du travail, norme AFNOR X35-109 et décret n° 92-958 du 3 septembre
1992)
• Boys
• From age 14 to 15: 15 kg
• From age 16 to 17: 20 kg
• Men
• Max 55 kg
• May be allowed to carry loads above 55 kg, if recognized able to do so by the
occupational physician
• In any case the load shall not exceed 105 kg. Article R. 231-72 of «code du travail» says:
«Lorsque le recours à la manutention manuelle est inévitable, et que les aides
mécaniques ne peuvent pas être mises en oeuvre, un travailleur ne peut être admis à
porter d’une façon habituelle des charges supérieures à 55 kgs, qu’à condition d’y avoir
été reconnu apte par le médecin du travail, sans que ces charges puissent être
supérieures à 105 kgs»

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Recommendations for manual handling of
loads

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Real case: bus bars in ISR
• When: March 2012
• Need: remove 16-m long bus bars from storage in the ISR
(B181)
• Action: 3 persons intervene, one of
them climb on wooden crates to
reach the bb stored in height
• Accident: a person falls down
between crates
• Safety rules for work in height were
somehow neglected
• Consequence: the person was absent for 7 weeks

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Heavy Handling

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Heavy Handling Section – EN-HE-HH
• http://
en-dep.web.cern.ch/en-dep/Groups/HE/Sections/H
H/he_hh_mandate.htm
• In principle, any overhead crane is driven by a
professional from EN-HE-HH
• However, a specific training course “pontier-
élingueur” is available and allows using overhead
cranes of up to 20 t
• Authorizations to operate a crane are given
exclusively by the EN-HE Group Leader, CERN-
wide, for a specific crane (we do not get
authorization for any crane on the CERN site)
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Design/use of handling tools/girders
• May not be used if not formally approved by
HSE
• CE conformity required
• Load test needed
• Design work may be done
on our side; however, one
needs to follow codes and
norms in force for
handling/lifting equipment
• Again, support from HSE is possible

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Norms regarding lifting / handling

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Some concluding words …

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Put priorities in the right order!
• No room for procrastination* in safety
• Safety first, remember the ranking put in
force for LS1: Yo u r
1. SAFETY l th ,
hea egrity,
2. QUALITY
a l i n t
si c
3. SCHEDULE phy life !
r n ed
4. COST
o n c e
are c
• *Procrastination:
• The action of delaying or postponing something
• The practice of carrying out less urgent tasks in preference to more urgent ones,
or doing more pleasurable things in place of less pleasurable ones, and thus
putting off impending tasks to a later time
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Things to remember
• Act as a professional, qualification and
training are essential to ensure safety at the
workplace
• Do not improvise if you are not sure of what
you do (or are asked to do), always ask to
experienced staff in case of doubt
• Safety is the matter of all
• You can always talk to your supervisor, section
leader, group leader, Territorial Safety Officer,
Departmental Safety Officer (Thomas Otto)

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Useful links
• HSE: Occupational Health and Safety and Environmental
Protection Unit
• https://espace.cern.ch/hse-unit/en/Pages/SafetyinDepartments.aspx
• In particular safety rules https://
espace.cern.ch/Safety-Rules-Regulations/en/Pages/default.aspx , and
• Regulatory watch that provides you with a list of referenced
documents (laws, standards, guides, ...) applicable in matters of
Safety: https://
espace.cern.ch/Safety-Rules-Regulations/en/regulatorywatch/Pages/r
egulWatch.aspx
• Call them in case of doubt
• Departmental safety plan – TE
• http://
safety-commission.web.cern.ch/safety-commission/SafetyPlan/te/e_in
dex.htm

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