A guide to… Maintenance Safety

Aim There is a legal requirement for regular and effective maintenance, inspection and testing of work equipment. This training tool covers: Legislation, Testing and Inspection Introduction Dangers of Maintenance Safety considerations in Maintenance Operations Testing and Inspection Controlling Maintenance Work Risks

Aim Legislation, Testing and Inspection Testing may involve operation of the equipment or the use of tools or equipment to measure or test a part or function of the equipment. Provision and Use of Work Equipment Regulations 1998 require employers to inspect their work equipment and have specific requirements for inspection of power presses. Lifting Operations and Lifting Equipment Regulations 1998 specify inspection of lifting equipment. Inspection and testing of safety devices is particularly important.

Aim Introduction Maintenance should be carried out on all plant, equipment and machinery to ensure its correct functioning and continued safe operation. The lack of regular maintenance has been identified as the major contributor to recent incidents that have resulted in the deaths of employees and members of the public By performing regular maintenance, hazards are removed at source and risks are reduced to a minimum.

Aim Dangers of Maintenance Many of the risk controls and protective devices must be removed or overridden to perform maintenance, increasing the risk to maintenance operatives. During maintenance, access will be gained to parts that are normally safe by position or guarding, thus posing a greater hazard. These hazards include hot or cold surfaces, sharp edges or hazardous substances normally contained within the equipment or items being maintained.

Aim Safety Considerations in Maintenance Operations Maintenance operations can cause obstruction in corridors, walkways or parts of the associated work area. Maintenance operatives should not be adversely affected by others walking past. Obstruction must not block a fire escape route; if this is not practicable, make suitable alternative escape arrangements. Hot work or use of flammable materials may increase the risk of fire. Consider risks to children if the general public has access to the area

Aim Safety Considerations in Maintenance Operations Parts of the equipment that are normally internal or adequately guarded may be exposed. These may be static hazards, e.g. sharp edges, radiation and hazardous substances. They also may be moving hazards; exposure to moving parts is to be avoided where practicable as it risks entrapment. Risks due to remote hazards fall into two main areas — those posed by remote operation of equipment, and remote application of power or ingress of materials into the part of the equipment being worked on.

Aim Controlling Maintenance Work Risks Follow the 8 basic risk assessment principles: 1)Identify the hazards. 2)Identify those that will be affected by the hazards. 3)Evaluate the risks the hazards pose. 4)Determine and implement suitable means to adequately control the risk so far as is reasonably practicable. 5)Monitor the risk controls to ensure that they are, and remain, suitable and sufficient. Continued…

Aim Controlling Maintenance Work Risks 6)If the machinery is large and has many hazardous areas, a key exchange (trapped key) system may be required. 7)If it is impossible to eliminate or exclude the hazard, employ a safe system of work. 8)Supervision should be directly proportional to the risks involved and the competence and experience of the maintenance staff.