TE-MSC Safety Day Mechanical and Handling Hazards TE-MSC Safety Day Mechanical and Handling Hazards

TE-MSC Safety Day Mechanical and Handling Hazards - PowerPoint Presentation

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TE-MSC Safety Day Mechanical and Handling Hazards - PPT Presentation

F Savary Part I Mechanical hazards 1892014 Mechanical and Handling Hazards 2 Definition A mechanical hazard is any hazard involving a machine or process Are essentially due to machine components of the machine ID: 1015793

2014mechanical handling cern safety handling 2014mechanical safety cern hazards18 welding pressure machine tools case machines mechanical due hazards skin




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1. TE-MSC Safety DayMechanical and Handling HazardsF. Savary

2. Part I: Mechanical hazards18/9/2014Mechanical and Handling Hazards2

3. DefinitionA mechanical hazard is any hazard involving a machine or processAre essentially due to machine, components of the machine, moving parts of the machine, or any other source, which can injure a personCompressed gases or liquids can also be considered a mechanical hazardMechanical and Handling Hazards18/9/20143Types of mechanical injuries

4. Machining* operationsConventional and CNC machine tools … but also folding presses, rolling machines, and cabling machines are other typesThere 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, glovesMechanical and Handling Hazards18/9/20144*Or more generally, operations on/with machinery/tools

5. Some materials are more aggressiveFiberglass and composite materialsrequire particular precautionsAlways wear respirator/face mask,and gogglesMany resins are inflammable or contain additives that are inflammable, so be careful with heat sourcesMany 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!18/9/2014Mechanical and Handling Hazards5

6. Heavy loads may fall on the floor!18/9/2014Mechanical and Handling Hazards6… and worst, on your foot!

7. Welding, soldering, brazingPersonal 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 areaSoldering, 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 alcoholMechanical and Handling Hazards18/9/20147

8. Welding press for dipole shells, 1On top of obvious welding related hazardsMechanical hazards due to the necessity for the welder to watch carefully the weld pool during welding, …in a small space18/9/2014Mechanical and Handling Hazards8

9. Welding press for dipole shells, 218/9/2014Mechanical and Handling Hazards9emergency cable pull switchHelp is recommended in certain circumstances … allocate sufficient resources

10. Hydraulic and pneumatic systems, 118/9/2014Mechanical and Handling Hazards10Collaring press:Up to 375 MN over 15 m!High pressure up to 700 barHydraulic group of the welding press:Up to 162 MN over 16 mHigh pressure up to 550 bar

11. Hydraulic and pneumatic systems, 2High pressure fluids hazards, hydraulically and pneumatically driven tools hazardsCrushing, high pressure / hot fluid leaks / jetsMechanical and Handling Hazards18/9/201411High pressure oil easily punctures skin causing serious injury, gangrene or deathIf injured, seek emergency medical help. Immediate surgery is required to remove oilDo not use finger or skin to check for leaksLower load or relieve hydraulic pressure before loosening fittings

12. Real case: pressure testWhen: March 2007Where: LHC tunnelNeed: verify/accept triplets after installation in the tunnel Action: carry out pressure testIncident: due to movement of one of the cold masses, rupture of a helium piping withstrong detonationConsequence: 2 of the 7 persons who witnessed the test (even if at 25 m of the incident) presentedsigns of hearing loss (that disappeared after some time). Only one of the seven was wearing hearingprotectionMechanical and Handling Hazards18/9/201412

13. Machine conformity – Mise en conformité des machinesTo be checked with EN-MME, Emmanuel Ravry / Alain StalderSafety Form M-4-0-2 - Workshop machine tool - Authorization of useMechanical and Handling Hazards18/9/201413

14. For new and special machinesFor example, a 6.5 m long reaction furnace currently in assembly in B180Risk assessment file shall be developed by the manufacturerThere are guidelines available at:https://edms.cern.ch/document/1114042/3: Safety Guideline on risk assessmenthttps://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 workshops18/9/2014Mechanical and Handling Hazards14

15. Safety form – Risk assessment form18/9/2014Mechanical and Handling Hazards15

16. See next presentation by John Pedersen18/9/2014Mechanical and Handling Hazards16

17. Part II: Handling hazards18/9/2014Mechanical and Handling Hazards17

18. DefinitionManual handling of loads (MHL) and manualmaterial handling (MMH) involve the use of thehuman body to lift, lower, fill, empty, or carry loadsWhen performed incorrectly or excessively, these tasks may expose workers to physical risk factors, fatigue, and injuryA variety of MMH techniques and tools exist to alleviate these potential problemsForklifts, overhead cranes, lifting girders,SpanSet® slings, …18/9/2014Mechanical and Handling Hazards18

19. Manual handling and liftingThere 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)BoysFrom age 14 to 15: 15 kgFrom age 16 to 17: 20 kgMenMax 55 kgMay be allowed to carry loads above 55 kg, if recognized able to do so by the occupational physicianIn 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»Mechanical and Handling Hazards18/9/201419

20. Recommendations for manual handling of loads18/9/2014Mechanical and Handling Hazards20

21. Real case: bus bars in ISRWhen: March 2012Need: 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 heightAccident: a person falls down between cratesSafety rules for work in height weresomehow neglectedConsequence: the person was absent for 7 weeks18/9/2014Mechanical and Handling Hazards21

22. Heavy Handling18/9/2014Mechanical and Handling Hazards22

23. Heavy Handling Section – EN-HE-HHhttp://en-dep.web.cern.ch/en-dep/Groups/HE/Sections/HH/he_hh_mandate.htmIn principle, any overhead crane is driven by a professional from EN-HE-HHHowever, a specific training course “pontier-élingueur” is available and allows using overhead cranes of up to 20 tAuthorizations 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)18/9/2014Mechanical and Handling Hazards23

24. Design/use of handling tools/girdersMay not be used if not formally approved by HSECE conformity requiredLoad test neededDesign work may be done on our side; however, one needs to follow codes and norms in force for handling/lifting equipmentAgain, support from HSE is possible18/9/2014Mechanical and Handling Hazards24

25. Norms regarding lifting / handling18/9/2014Mechanical and Handling Hazards25

26. Some concluding words …18/9/2014Mechanical and Handling Hazards26

27. Put priorities in the right order!No room for procrastination* in safetySafety first, remember the ranking put in force for LS1:SAFETYQUALITYSCHEDULECOST18/9/2014Mechanical and Handling Hazards27*Procrastination:The action of delaying or postponing somethingThe 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 Yourhealth,physical integrity,lifeare concerned!

28. Things to rememberAct as a professional, qualification and training are essential to ensure safety at the workplaceDo not improvise if you are not sure of what you do (or are asked to do), always ask to experienced staff in case of doubtSafety is the matter of allYou can always talk to your supervisor, section leader, group leader, Territorial Safety Officer, Departmental Safety Officer (Thomas Otto)18/9/2014Mechanical and Handling Hazards28

29. Useful linksHSE: Occupational Health and Safety and Environmental Protection Unithttps://espace.cern.ch/hse-unit/en/Pages/SafetyinDepartments.aspxIn particular safety rules https://espace.cern.ch/Safety-Rules-Regulations/en/Pages/default.aspx, andRegulatory 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/regulWatch.aspxCall them in case of doubtDepartmental safety plan – TEhttp://safety-commission.web.cern.ch/safety-commission/SafetyPlan/te/e_index.htm18/9/2014Mechanical and Handling Hazards29