Guarding machines

and maintenance workers

Mechanical Fixed guards for Machine, 09 Aug 2017
Machine Safe guards – a glimpse
Introduction

• Machines improve the production efficiency in the Brewery.

• However, their moving parts, sharp edges, and hot surfaces cause serious workplace injuries such as crushed fingers

or hands, amputations, burns, or blindness and also fatality.

• Half of the reported Injury/accidents are due to lack of machine safeguards*.

• Safeguards are essential to protect workers from injury.

• Any machine part, function, or process that might cause injury should be safeguarded.

* - OSHAS statistics report

Machine Man accidents
Causes of Machine accidents

• Reaching in to “Danger Zones” of equipment.

• Not using Lockout/Tagout.

• Unauthorized person doing maintenance or using the machines.

• Missing or loose machine guards.

• Lack of training.

Prevention of Machine accidents

o Any machine part, function, or process which may cause injury must be safeguarded.

o Where the operation of a machine can injure the operator or other workers, the hazard must be controlled or
eliminated.
Machine Hazards
Three basic areas in machines needs to be safeguarded

• Point of operation like cutting, boring, shaping…etc

• Power Transmission apparatus like flywheel, pulley, belts, shafts, coupling, cams, spindles, chains, cranks and gears.

• Other moving parts includes rotating, reciprocating and transverse moving parts.

Major Hazards for workers

• Entanglement in rotating parts.

• Being caught between two parts moving past one another in a shearing action.

• Being crushed between machinery or parts as they move towards a fixed part or structure.
Guarding requirement
• Create No New Hazards – Guard should not create a new hazard such as a shear or nip
point or a sharp, jagged edge.

• Create No Interference – Safeguard should not prohibit operator from performing

his/her job safely and efficiently.

• Allow Safe Lubrication – Operators should be able to lubricate the machine without
removing the guards.

Confirm to the Indian Standard – IS 9474:1980 : Principles of Machine Guarding

Legal and other requirement
A. Under various provision of Indian Factories act,1948 B. OSHA Standard - 1910.212

The Statutory requirements are: To protect the operator and other employees from hazards such
as those created by:
1. Sec. 21 – Fencing of machinery
1. Point of operation
2. Sec. 22 – Work on or near machinery in motion.
2. Ingoing nip points
3. Sec. 23 – Employment of young persons on dangerous machines.
3. Rotating parts
4. Sec. 24 – Striking gears and devices for cutting off power.
4. Flying chips or sparks
5. Sec. 25 – Self acting machines.
C. ISO standard – 14120:2015
6. Sec. 26 – Casing of new machinery.
General requirements for the
7. Sec. 30 – Revolving machinery. design and construction of fixed and movable guards

8. Sec. 35 – Protection of eyes.

Types of Safeguards
Fixed Safeguards
• a permanent physical barrier to prevent intentional or unintentional access.
• The fixed barrier should not interfere the operation and
• Normally 3600 covering is provided to ensure protection.
• Small opening is provided for feed of materials or maintenance purposes.

Interlocked Safeguards
• Designed to give ready to access to machine danger zones whilst ensuring safety of the operator.
• when running the interlock remains shut and on intervention gets activated.
• Machines cannot start unless guards are back in position.

Safety Devices
• Sensing devices like photoelectric, radio frequency and electromechanical is used to shut down the
instrument when interfered or entered into work.
• In the event of power failure or malfunction, the machine guarding system should ‘fail to safe’ render
the machine or parts inoperable until power is restored or guarding system is ready.

Two hand control system

• This require constant two-hand pressure of operator during the entire machine cycle.
• with this kind of control the operator must not be able to activate the machine and then reach the
danger zone whilst a danger still exists
• This system designed to protect the operator so people who are not operating the machine needs
suitable protection from danger.
Mechanical Fixed Safeguards – Standard as per IS 9474:1980
Fixed Guards
Standard Frame and mesh guard

Advantages Disadvantages
• Maximum protection • Poor visibility
• Variety of applications • Must remove for repairs requiring LOTO
• In-house fabrication
• Low cost & maintenance

Standard mesh clearance

OSHA 3067

   
Fixed Guards - specifications
# Description Type Material Specification Coating Other Conditions

Small Guards
Height less than or Mild steel Rod 1 cm diameter
equal to 75 cm Powder coat
Or Yellow code
Surface area less
than 1 m2 Mild steel Angle 20 x 20 x 3 mm

Braced Guards Mild steel Angle 25 x 25 x 3 mm

Height more than
or equal to 75 cm Powder coat Guard rigidly braced
1 Frame work Or Yellow code every 90cm.
Surface area more Mild Steel Pipe -
than 1 m2 20 mm Inside Diameter
seamless

Unbraced Guards Mild steel Angle 38 x 38 x 3 mm

Guard is fastened
to the floor or
working platform
without any Mild Steel Pipe -
support or bracing 38 mm Inside Diameter
seamless
Fixed Guards - specifications

# Description Type Material Specification Coating Other Conditions

Solid or Perforated Metal 1 mm in thickness and for expanded metal 1.25mm Powder coat
sheet yellow code

Emulsion
Black code
2 mm diameter wire woven to diamond or square
Woven wire Metal pattern 10 mm or heavier mesh. or Plastic
2 Panelling coat in
green code
Fastening to frame
Plastic or Poly
carbonate or Rivets/bolts: 125mm
View glass Minimum thickness 6 mm. center to center.
toughened
Welding : every
safety glass
alternate 100mm
Fixed Guards - specifications

# Description Type Material Specification Coating Other Conditions

Powder coat
Belt width upto 25 MS Angle Frame work: 25 x 25 x 5 mm Shades of
cm Guard support : 38 x 6 mm
grey

Over 25 cm and Frame work: 38 x 38 x 6 mm Powder coat

Belt guards for MS Angle Shades of
horizontal upto 35 cm Guard support : 50 x 8 mm
grey
overhead
belts, ropes or Powder coat
chains. Over 35 cm and MS Angle Frame work: 50 x 50 x 8 mm Shades of
3 upto 60 cm Guard support : 50 x 10 mm
grey

Powder coat
Frame work: 80 x 80 x 10 mm
Over 60 cm MS Angle Guard support : 65 x 10 mm Shades of
grey

Belt guard Powder coat

panelling Solid sheet Metal sheet Minimum 1 mm thickness Shades of
grey
Standard guarding system
Mechanical Fixed Safeguards – Standards in UBL
Standard in UBL…
Drive
# type Location Machine / Equipment Required Guard Present Picture Recommendation

NH3 Compressor
RAC, Utility, Frame and mesh
1.
Belt and CO2 Plant and CO2 Compressor complete covering
Pulley Air Compressor
ETP with inspection door
Air blower

Utility, Brew
2.
Shaft and house, mill Fluid Transfer Pumps, Shuffler Coupling guard with
coupling house and and sealer inspection door
bottling

1. Frame and
3.
Shaft and Utility Cooling tower fan and air wire/mesh
Impeller blower
2. Std. Hand rail
Standards in UBL…
Machine /
# Drive type Location Equipment Required Guard Present Picture Recommendation

4.
Shaft and Utility and boiler Air handling units Frame and wire
Impeller house and Burners

5.
Shaft and All Induction motor Frame and wire
Impeller

6.
Shaft and All Industrial Fan Fine fabric mesh
Impeller over the frame
Standards in UBL…
Machine /
# Drive type Location Equipment Required Guard Present Picture Recommendation

Agitator and rack

7.
Chain and Brew house, ETP arm (LT, ETP – Frame and
sprocket and Bottling plant mesh/plate
clarifier and HRSCC)
Outside environment

Chains,
9. roller and Bottling plant bottle/can conveyor End plate covering
in the nip points
sprocket
Guarding opportunities

Mesh size is big enough for No guard available in the No coupling guard available in Guard not completely
passage of finger and guard belt/pulley and flywheel end. between motor and pump. covered.
not fully covered.

No proper guard in the nip No proper guard in the

end of chain conveyor. No proper guard in the nip No proper guard in the roller
end of chain conveyor. bearing end of motor in chain end of chain conveyor.
Potential hazard of hand conveyor.
caught in between.
“Which way will you go?”

OR
End of Document