1. Introduction
The employer is obliged to ensure that the used machines and other work equipment meet the requirements related to safe and hygienic working conditions, in particular concerning the protection of workers against injuries, effects of hazardous chemicals, electric shock, excessive noise, mechanical vibration, radiation as well as harmful and dangerous effects of other factors of the working environment, and that the ergonomic principles were taken into account within their structures. For machines that do not meet safety requirements, the employer has to equip all the machinery with adequate protective and working equipment.
Machines should be selected properly and adapted to the type of performed work. Any user (employer) should take into account all the specific conditions that occur and the type of performed work. It is also important to take into account the potential risks arising from the use of the machine in a particular working place. In addition, the following aspects have to also be considered:
· spatial conditions at the place of installation of the machine to carry out operating and cleaning actions as well as repairs and maintenance,
· issues of safe delivery and return of energy as well as raw materials and products,
· technical parameters of the machine,
· requirements for operators (e.g. qualifications, experience, physical and motoric fitness, physical and technical efficiency).
If the employer buys machines which are new or upgraded by the user in the EU they should meet the essential requirements of Directive 2006/42/EC. If used machines are purchased from countries outside the European Union (new, modified and used), it must be taken into account that they should meet essential requirements. If the user buys or uses some "old" machines in the EU, it should be adjusted to the minimum safety requirements specified in Directive 2009/104/EC. It should also be noted that the term machine in accordance with the aforementioned Regulation should be understood as all machines and other technical equipment, tools and installations used at work, as well as equipment for temporary work at height, in particular, ladders and scaffolding.
In the case of purchasing new machinery and other new work equipment, they must comply with the requirements for conformity assessment. It means that before purchasing a new machine the employer should carry out an inspection in order to verify whether:
· the machine is labelled with the CE mark and whether it includes the data to identity the manufacturer,
· it is accompanied by a DTR (the operating manual) and statements of compliance in Polish,
· the control elements and other information (description of controls, warnings, prohibitions, orders) are written on the machine in the language of the operator,
· the machine meets "at a glance" safety requirements such as preventing access to danger zones, being equipped with the required control elements (e.g. an emergency stop control device).
With a whole machine park consisting of new and used machines the user (employer) must keep them at the essential (required for newly produced and imported from outside the EU machines) or minimal (required for used machines) level.
Ensuring the safety of use of the machine park and other work equipment requires them to be well matched for the specific job. Thus by "the use of machinery" it is meant the performance of all activities related to the machine, in particular, shutting it on and off, operating it, transporting it, conducting repairs, modernization, modification, maintenance and handling, including cleaning.
Sometimes it may be necessary to correct the adjustment to a different operating environment by using additional protective measures. These may be measures recommended by the manufacturer of new machines or defined for used machinery, resulting in hazard identification and assessment of the corresponding professional risks. In order to keep machinery and other equipment capable of working in compliance with the relevant health and safety requirements, the necessary monitoring must be provided from the moment of installation at the working station. Furthermore, the employer is obliged to systematically monitor the safety and occupational health conditions, with particular emphasis on the organization of work processes, the technical condition of machinery and other equipment, as well as to identify ways of registration of non-conformities and methods for their improvement. If any imminent threat to life or health of workers is found, the person who manages the employees is obliged to stop the work process immediately and undertake action to remove this threat.
2. Inspections of machines installed at the working station
Directive 2009/104/EC requires different types of controls for machinery and other work equipment at the working station. The employer is responsible for monitoring the compliance of the machinery with the minimum requirements of safety and occupational health. In addition to improving the safety and health protection, controls can result in the withdrawal of the use of work equipment in any case where it has been irreversibly damaged and worn out or the permissible date for its use has expired. The employer (user) should therefore carry out the following checks.
Preliminary checks
It is performed after installation but before the initial start (being put into service for the first time). It is also necessary when assembled elsewhere. It is also important to carry out such inspections in case of change of location of the machine or other work equipment. If the safe use depends on the installation conditions, the user should make sure that the machine is properly installed and is operating properly and does not cause any additional hazards. These actions are necessary due to the requirements of 2009/104/EC, which stipulate that the machines made available to employees at the workplace or at a place designated by the employer:
· are suitable to perform the work or properly adapted to it;
· can be used without compromising the safety or health of workers,
· should also take into account the specific conditions of work, and in particular the existing risks relevant to the safety and health of workers.
Preliminary checks allow you to apply appropriate solutions to minimize the risks associated with the use of machines if the machine cannot be operated without risking the safety or health of workers.
Periodical check
It is conducted when the machine or other working equipment are used in conditions that may cause a risk due to the deterioration of its properties (technical). Its realization may also require performing certain tests.
Periodic checks make it possible to carry out permanent controls of machine's condition and keeping them in proper condition that guarantees their operational safety. The frequency of periodic inspections depends on the type of machines and on how they are used. In this case, the law does not stipulate any requirements. When setting deadlines for inspections, the recommendations of manufacturer should be considered.
Special checks
It should be carried out whenever there are special circumstances which may deteriorate safety conditions. This can occur in various situations, such as:
3. Methodology of control of machines used
Conductors of control activities
Controls should be carried out by individuals acting under separate national rules. If such do not exist, the employer should make sure that these activities were carried out by authorized and properly qualified employees. This is especially true when the operation, repair, renovation or maintenance of machines cause a risk to the safety or health of workers.
Ensuring safety when conducting inspections
The professional risk minimization is also possible by planning how to perform these activities with the use of technical and organizational solutions.
An example of such technical solutions application can be the commonly used systems for maintenance and repair of machines to prevent accidental operation by unauthorized persons. These include the so called Lockout / Tagout (LOTO) procedures for securing machines. The lockout provides disconnecting the machine from the power supply in order to prevent it from running until all of the blocking elements can be removed (e.g. padlocks, valve locks, locks, links). The tagout involves placing the appropriate markings on the lock mounted on the element that controls the tributary of energy. Such marking informs about the block and that no element or unit to which energy is supplied can be restored to operation by removing blockages and markings.
For the control of large machines, special attention must be paid to the safety of access points to places of performing controls regarding passes, bridges and intersections.
Determining the control activities and manner of their execution
An important task while the planning and organization of controls is also ensuring that these activities can be carried out throughout the required range regarding the machine's examination, functional testing and measurements.
Types of control activities which machines are subject to may be specified in the technical and physical documentation or the manual prepared by the manufacturer. In this regard, also detailed rules , recommendations or guidelines for the industry may be helpful.
Safety aspects taken into account during the control
The control scope is
determined on the basis of the requirements of Directives 2009/104/EC and
2006/42/EC, taking into account whether it meets the following listed and
described aspects. When controlling specific groups of machines,
the requirements of specific national regulations can also be taken into
account.
Covers or additional forms of protection against dangerous elements
· Movable elements and other parts that pose a risk in the event of contact with them should be up to a height of at least 2.5 meters from the floor level of the working station platform covered or provided with other effective protective fitting.
· Installed covers (fixed or movable) or other protective fittings (the so called technical barrier protective measures) prevent contact with hazardous moving parts, e.g. power transmission elements (shafts, couplings, gears, pulleys, chains, etc.) and elements in the working area (tools, workpieces). Covers must meet the following requirements: used materials should conform to the conditions of the working process (temperature resistance, corrosion resistance, abrasion resistance, suitable strength, toughness, etc.), no sharp edges and corners, reliable fastening to the machine when it's being operated (protection against unexpected opening, falling away, repositioning, etc.), positioning in relation to the danger zone (movable parts) with the so called safety distances specified in Polish Norms, the possibility of convenient observation of the operation process by selecting the appropriate shape and position, the use of transparent materials or openings in the cover, selecting the type of cover according to the frequency of access to the danger zone (fixed cover, movable cover, blocking cover, movable blocking cover with the lock, movable automatic cover, cover with a control unit), adjustment to the number and location of hazardous areas (spot cover, total barrier cover).
· Parts made from materials with proper mechanical properties, resistant to corrosion, wear, etc. and matching the specific operating conditions (pressure, speed, temperature, humidity, etc.). For the protection against hazards, use a properly selected cover of the appropriate construction and strength in the expected zones of separation or disintegration of machine parts.
· Tools and workpieces secured in properly selected grips, instruments or tables with mounting holes. Workpieces may also require using rails and steady rests. It is also necessary to use some recoil protection fittings such as pawls or splitting wedges, depending on the workpiece.
· Fittings limiting the location used to protect from crossing the border positions and from falling some of the machine parts and devices down (with sledges, rails, etc.).
· Fittings limiting the position of the transported materials and products (from conveyors, cranes, etc.) and covers (shields, enclosures) of hazardous areas of sufficient strength (allowing the absorption of the energy of the ejected objects and tools).
Control elements and necessary protection equipment in case of emergencies
· A system of overcharge switches to stop the equipment immediately (e.g. brakes), etc.
· An emergency stop device, due to hazards posed by the machine (the elements in motion, drives, movable tools or materials processed), depending on the time needed to stop them.
· Control elements for an emergency stop - easily accessible - in all the places and positions taken by the operators (e.g. control panel, site of delivery and reception of materials) as well as in places not visible from the working stations.
· An emergency stop device - effective and regardless of the type of machine operation shall exclude all of its dangerous movements.
· Emergency stop control device - red on a yellow background, standing out by the shape (mushroom-shaped button).
Other characteristics of the control elements
· Marked (in clearly legible inscriptions in Polish or with understandable symbols). Markings placed on the elements above or below them.
· The appropriate colour of control elements indicating their purpose is applied. The control device to switch on (run) - green or white (grey or black is also acceptable). The control device to switch off (stop) - red or black (also acceptable grey or white).
· Control elements - location - the operator cannot be exposed to contact with hazardous components of machinery and equipment (e.g. movable parts of the drive, tools, sharp edges and corners, electrically live parts, hot surfaces, aggressive chemicals, etc.).
· Control elements - protection against accidental change of position. This can be done by: indentating buttons in the cabinet or in the flanges, maintaining sufficient distance between control components (preventing unintentional start a few of them), ensuring proper minimum run force (5 N), covering the pedals, using the double-acting control lever (two different movements need to be performed in order to switch it on), the use of confirmatory button (manual or foot), mechanical protection in the off position (e.g. key locks).
Starting the machine
· The construction of the control system prevents the machine from starting in an unpredictable and automatic way in hazardous conditions (the movement of tools, workpieces, etc.).
· Unexpected switch on can be prevented by: rectifying a control system fault, the resumption of power supply, performing the emergency stop, activation of protective devices in hazardous conditions (blocking, non-contact protective devices), closing the movable blocking covers.
· The movement of working elements immediately after connecting the machine to the power source is prevented (without activating the start signal via a control element). This requirement can also be met by switching the type of machine operation and the significant changes of the operating parameters (speed, temperature, pressure).
Switching the machine off in a regular way
· The machine is equipped with a control system that stops it completely and safely.
· It is equipped with control elements that stop the whole machine or parts thereof, depending on the type of hazard, so that the machine is safe.
· Power supply to the respective drives of the machine is disconnected in the event of stopping the machine or its hazardous parts. Control elements are located in a way that enables the operator to see the detained items.
· Stop function (STOP) has priority over the start function (START). This means that if the START and STOP buttons on the control device are pushed at the same time, the machine won't switch on and if it is being operated - it should automatically switch off.
· Activating the machine switch off system does not cause hazards such as effects of rapid response of inertia forces or the presence of residues of other energy types (loosening, slipping of tools and objects in the holders, breaking of tools, collision of materials and workpieces, loss of stability of the workpieces, etc.).
Visibility at the hazardous area from the operator's working station
· The control panel is located so that the operator has the opportunity to observe all working stations and to verify whether in hazardous areas other people are not present.
· If such verification is not possible, a safe system automatically sends an acoustic or optical warning signal before starting the machine, which can be received from all positions of the machinery operation. The time between giving the signal and the start-up should be long enough so that a person exposed to such hazard could avoid it, e.g. leave the danger zone or prevent starting the machine (emergency stop buttons at the workplace).
Warning signals
· Light and/or acoustic signals indicating hazardous situations (running machine, parameters change, failure) is selected so that the generated signals are unambiguous and easily noticed and distinguished from other signals.
· The intermittent light signal (flasher) is used to inform about a greater risk or more urgent need for intervention and the constant signal indicates a lower risk.
· Sound signal of variable frequency has priority over a fixed frequency signal.
· Constant warning signal is used to inform about the necessity to evacuate.
· Light warning devices at all locations are easy to notice.
· Each colour of the light signal has a different meaning: red - failure, malfunction (an emergency), yellow - warning (abnormal state, the upcoming emergency situation), green - security status (normal), blue - a condition in which the operator action is necessary (informing about the need for action by the operator).
Control systems
· A proper control system needs to be provided in order to exclude the hazardous operation of the machine and keep safety features within the entire range of work performed and terms on using the machine (temperature, humidity, vibration, shock, electromagnetic fields, etc.).
· Elements of the control system implementing the safety functions have reasonable resistance to defects (e.g. loss of or fluctuations in power supply, short circuit between the conductors, failure of a contactor, relay or splitter, failure in disconnecting the safety switch, springs rupture, software malfunction).
Compliance with the requirements of ergonomics
· The construction of the machine complies with the regulations and standards of occupational health and safety, as well as the standards of ergonomics.
No unauthorized changes in construction
· There has been no in-house change in construction (structure) of the machine or other technical devices that could lower the safety level.
· Any structural modifications were preceded by an assessment in terms of health and safety in the manner specified by the employer.
Operation and maintenance documentation
· The employer has the operation and maintenance documentation of machinery and technical equipment operated in the workplace, as well as data relating to whether the installation, operation and maintenance of these machines are compliant with this documentation.
Instructions on occupational health and safety
· The employer has developed current instructions on occupational health and safety concerning operation of machines and other technical equipment in service at the plant, and made them available to employees for permanent use
· These instructions properly define the actions to be executed before starting the work, the principles and methods of safe performance of the job, actions to do after finishing the work and, in particular, the rules of conduct in emergency situations posing a threat to life or health of workers.
Dealing with withdrawn from use machines
· Machines pointed by the employer as faulty, damaged or being at repairs are withdrawn from use and clearly marked with information boards and protected in a way that prevents their start.
Commissioning report
· Operated machines or technical equipment have been subjected to technical commissioning by a specialist before being put into use in the plant, in particular as regards technical machinery and equipment subject to registration or technical commissioning by specialized bodies, e.g. the Office of Technical Inspection, based on the instructions contained in the Act on Technical Inspection.
Inspection and testing of machine's technical condition
· Inspections and check-ups of technical condition of exploited in the workplace machinery and other technical devices are carried out within the periods specified in the regulations on their operation or in their operation and maintenance documentation as well as within the periods specified in commissioning reports issued by specialized authorities.
The compliance assessment of new machines used
· Machinery and equipment that has been provided to working stations meet the requirements for assessment of compliance with regulations and standards.
Emissions or ejection of substances, materials
· Machines do not emit into the environment substances hazardous to health at levels that exceed acceptable hygienic norms.
· The employee is protected against mechanical and thermal impact. This applies particularly to containers with liquids or gases and pipes at a pressure (both rigid and flexible pipes and connections between tanks and equipment). This can be achieved e.g. by changing the location of work stations in relation to sources of hazards, by using covers, isolation, etc.
· Pipes with utilities at a pressure are appropriately attached, e.g. by means of holders, hooks, supports, etc. In places where the steam, water, liquid metals, plastics and other substances at a pressure are thrown out, additional casings, screens, covers, etc., should be applied.
· Casings, extractor hoods, suction and other devices (intercepting agents harmful to health) located near the emission sources and cooperating with the retraction system devices should be used.
Stability
· The machine exposed to overturn or unintended movements under the influence of internal and external forces (e.g. due to wind pressure, vibration, shock, load) is attached to the ground (using brackets, anchors, screws).
Lighting of work stations
· Spot lighting is provided (when the general lighting does not provide proper lighting parameters on work stations and zones where the adjustments, maintenance and repairs are performed) as well as the type of light sources (incandescent, discharge) and luminaries (regarding regulations and standards and the results of lighting measurements) which isappropriate for the type and location of the activities carried out.
Temperature extremes
· Human contact with the elements of a very high or very low temperatures (flame, hot products and waste, tools, installations) has been prevented, e.g. by using casings, covers or screens as well as insulating materials (inside or outside devices).
· Machines positioned in such way as to eliminate the need for the presence of an operator at the site of exposure. Zones (areas) presenting hazards should be appropriately marked.
Use of machines
· Machinery and equipment shall be applied in accordance with the guidelines and recommendations specified by the machine manufacturer in the operating manual.
Isolation of energy sources
· Means for disconnecting electricity have been applied and properly marked (e.g. switch disconnectors, circuit breakers, plug-socket sets). For electrical machines with a capacity of less than 1 kW and a current of less than 16 A, the plug-socket system can be applied.
· The machines and equipment use devices that shut-off gas, liquid, steam and other energy carriers, and therefore they should be properly marked.
· The position of a device that disconnects the power supply should be marked in order to identify properly the "connected / disconnected" state. Devices for disconnecting the power sources should be locked in the disconnected position (e.g.. with a padlock).
Signs and other safety markings
· Safety signs and / or colours and other marks (pictograms, words) are applied when there is no chance to eliminate the risk with other protective measures.
· Safety signs (prohibition, warning, command, evacuation and information) comply with the models specified in the Polish standards.
· Safety markings are placed at the location of an identified hazard or in its immediate vicinity.
· Locations where a risk occurs of colliding with obstacles, falling down or of falling off, are marked with safety colours - diagonal stripes: yellow and black or red and white (stripes drawn at an angle of approx. 45° and having similar dimensions).
Access to the operating locations of machinery and equipment
· Maintenance (lubrication, adjustment, exchange and replenishment of fluids) is performed while the machine is switched off. Suitable control systems (if it is not possible to perform the work at a standstill) should be used (e.g. a step device that allows to limit the length of pathway of transporting a hazardous element or a support device that continues the movement of the hazardous element, provided that the control button is switched on).
· When performing maintenance works, use mechanical devices to prevent unintended change of the position of a hazardous part of the machine (e.g. by gravity, elasticity) such as wedges, supports, struts, handles, etc. In order to record any repairs, maintenance, fluid replacement, a maintenance log should be kept.
· Adequate space to walk or stand, reducing the risk of falling and slipping is provided (e.g. riffled plate, grille, non-slip mat).
· Access to work areas located on different levels is safe. This can be achieved by the using stairs, ladders and working platforms equipped with protective railings with a height of 1.1 m.
· In areas of works perfomed at height, anchorage points of personal protective equipment are mounted to prevent falls from height.
Fire, explosion and electric shock
· Electrical cables, wires for the transmission of gases, liquids and other utilities are protected from mechanical damage, the impact of fire and other factors (by carrying cables in floors, in pipes, hanging, etc.).
· Used installation and electrical appliances are adjusted to the existing hazards (e.g.. explosion-proof).
· Working stations are equipped with means of control and maintaining the right level of operating parameters (temperature, pressure, voltage and amperage, etc.).
· To protect against fire, explosion and electric shock, use such technical solutions that eliminate the hazards associated with electricity or prevent them (e.g. fire protection measures if a direct or indirect touch is possible, or locking the electrical equipment in order to prevent access to it).
· There are measures undertaken to eliminate or limit the the possibility of dangerous electrostatic charges or means for its discharge (preventing the accumulation loads or discharge).
Documentation of the controls results
Documented results of controls should be kept for a period of 5 years from the date of completion of the control. It is expected that supervisors and auditors will be interested in the content of these protocols. However, if the machines are used outside the workplace, in place of their use a document should be available that confirms the completion of the last inspection of the machine.
Examples of follow-up actions to take in order to comply with minimum health and safety requirements for used machines
Example 1
Raising the movable cover of the handle in the metal lathe does not stop the machine (Fig. 1). The following requirement is not met: "If there is a risk of direct contact with movable machine parts, which could lead to accidents, use covers or other protective devices to prevent access to danger zones or to stop the dangerous parts movement". Locking device should be used in the cover which stops the movement of the machine and prevents it from starting when the cover of the workpiece in a lathe is opened.
Figure 1. The lathe operation is possible when the cover of the workpiece is opened: 1 – opened cover of the workpiece handle
Example 2
Access to the protruding rotating machine element (Fig. 2).
Figure 2. Uncovered rotating machine element : 1 – accessible rotating machine element
The following requirement is not met: "If there is a risk of direct contact with movable machine parts, which could lead to accidents, use covers or other protective devices to prevent access to danger zones or to stop the dangerous parts movement".
A fixed cover of the rotating machine element should be used.
Example 3
Marking and colours of control elements on the desktop are no longer visible due to prolonged exposure to dust and other factors in the working station (Fig. 3)
Figure 3. Illegible control elements on the desktop of the machine.
The following requirement is not met: "Control elements which influence the safety of employees should be visible, easy to identify and properly marked"
The desktop and control elements must be cleaned. If it is necessary, complement the markings of control elements (with readable inscriptions in Polish or using understandable symbols - located on the control elements, above or below them) or replace these items (by using appropriate colours defining the purpose of control elements).
Example 4
Lack of protection of workers against electric shock (Fig. 4)
Figure 4. Unsecured cabinet with electrical equipment of the machine.
The following requirement is not met: "Machines are properly secured to protect workers from hazards arising from direct or indirect contact with electrical energy"
Replace the cabinet cover so that it meets the relevant requirements set by the IP Code (protection against access to live parts and ingress of dust and water) and it provides access to the equipment only to authorized persons (closed with key or special tool).
Example 5
Insulating main disconnecter cannot block the off-position (Fig. 5), which creates the possibility of unauthorized connection of the machine to a power source and posing a hazard e.g. to the employee conducting the machine service. The following requirement is not met: "Machines shall be equipped with easily recognizable devices for disconnecting the power sources; reconnecting the machine to energy sources cannot pose a hazard to workers".
Figure 4. Insulating main disconnecter with no possibility to block the off-position.
The insulating main disconnecter with block the off-position option must be installed.
Example 6
During repair, e.g. servicing or adjusting to comply with the minimum health and safety requirements specified in Directive 2009/104/EC, the modernized machine is subjected to significant changes resulting in the modification of its original technical characteristics or extension of its scope to include new useful features. It also creates new risks not included in the risk assessment for the machine. The employer merely prepares the documentation on those changes.
In this case, the commissioned machine can be considered as the so called new machine, and it should meet the essential requirements. In each case, modernization of the machine should be carried out taking into account potential changes in relevant parameters. If the modernized machine is considered to be a modified product, it should be seen as "new" and as such it should be placed on the market and/or put into service. The new status of the machine results in the necessity to meet the essential requirements under the Machinery Directive 2006/42/EC. This means that a person who modernizes the machine in a way which will lead to its modification is obliged to issue the declaration of conformity, mark it with the CE mark and prepare a manual.
Example 7
Workers have limited access to places of maintenance and set-up of the machine. The following requirement is not met: " Solutions should be applied to provide safe access and presence of workers in production areas as well as machine maintenance and set-up zones." Appropriate transition between the machine and other devices or walls intended only for operating such equipment should be provided. Floors should be of a flat, smooth, but not slippery surface.
Example 8
In the mill for plastics it is possible to access the cutting system by opening hopper what might result in the ejection of material to be shredded.The following requirement is not met: "If there is a risk of direct contact with movable machine parts which could lead to accidents, use covers or other protective devices to prevent access to danger zones or to stop the dangerous parts movement".
Access to the cutting system should be prevented by opening hopper through the use of additional fixed cover, mounting the support unit for feeding components for shredding, using a suitable pusher to push the item to be shredded. The risk of direct contact with moving machine parts can be significantly reduced by the use of emergency stop devices.
Plan of bringing into conformity (the verification of compliance) with minimum health and safety requirements
Bringing into conformity or verification of compliance of machinery and other equipment with the minimum requirements requires determination of inspected aspects, finding of non-compliances and proposing measures aiming at removing these inconsistencies. In difficult cases in which removal of non-compliances is not obvious, you need to conduct the occupational risk assessment in order to confirm the correctness of the actions carried out.
Schedule of periodic controls of machinery and other working equipment
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